Method and Apparatus to Effect Heat Transfer

ABSTRACT

The disclosed methods and apparatus seek to effect heat transfer through the use of one or more conductive fin devices. In addition, the disclosed devices seek to reduce the discharge of pollutants from primary combustion processes using carbonaceous fuel sources by implementing secondary combustion features and other apparatus. With more effective heat capture and utilization, the disclosed heat exchange technologies provide methods and apparatus to reduce heat dissipation to atmosphere. The methods and apparatus have application in the areas of industrial incineration, power boilers, water heaters, residential and commercial solid fuel waste heat recovery appliances, and electric power generation. In addition, the technology could have application in the areas of solar systems, desalination systems, aircraft and vehicular engines, electric motors, turbines, oil pans on internal combustion engines, transmission cooling pans, cooling navigational and electronic systems, and computer cooling and power supply.

FIELD OF ART

The disclosed apparatus and methods relate generally to the field of plate-type heat exchangers which can be conjoined with secondary combustion devices, and more specifically to such apparatus which are stand-alone devices or incorporated into one or more systems of devices.

BACKGROUND

Mechanisms for conversion of energy contained in fuels to mechanical work or electric energy necessarily produce large quantities of byproduct heat or waste heat. Presently, technology may utilize one or more heat exchangers to effect heat transfer from one medium to another. Although engineers have attempted to understand and control the flow of heat through the use of thermal insulation, heat exchangers, and other devices, it is well known that inefficiency has commonly been accepted as the norm. For example, it is well known that most of the time the electrical efficiency of thermal power plants, which is defined as the ratio between the input and output energy, only amounts to about 30% to about 40%. In addition, it is often difficult to find useful applications for the large quantities of low quality waste heat from these systems so the solution has been to reject waste heat to the environment. Usually, heat is rejected to water from a sea, lake, or river. This of course results in dissipative heating of the water body which may also be an environmental detriment. If sufficient cooling water is not available, the power plant would require cooling tower technology to reject waste heat to atmosphere. Although waste heat can typically be recovered if a cogeneration system is used, the use of byproduct heat is often limited due to difficulties in heat transport and heat storage. There are huge potentials of waste heat.

Mechanisms for conversion of energy contained in fuels can also produce unwanted pollutants. For example, it is well known that combustion involving a fuel and an oxidizer results in a transfer of energy. The fuel is usually a compound consisting of hydrogen and carbon and the oxidizer is often air. In trying to control combustion and the release of heat for beneficial use, the idea is to carefully control the amount of fuel that is being burned and try to keep the air-to-fuel ratio very close to the stoichiometric proportion or the ideal ratio of air to fuel. In an actual combustion process, however, it is not uncommon for the combustion of the fuel to be incomplete, resulting in unoxidized compounds and unburned fuel in the products. Impurities in the fuel, poor control of air-fuel ratio, incomplete combustion, and variation in the combustion temperature help to promote pollutants such as sulfur oxides, nitrogen oxides, carbon monoxide, and particulate matter.

With the recent global promotion of energy efficiency and protection of the environment, the role of heat exchangers in efficient utilization of energy has become increasingly important, particularly for energy intensive industries such as electric power generation, petrochemical, air conditioning/refrigeration, cryogenics, food, and manufacturing. Although many types of technology are currently available for the production of energy and/or heat, it is asserted that only little progress to conventional technology has been achieved over the last centuries because of the availability of cheap fuel sources. With rising energy costs, rising world temperatures, and the release of pollutants and carbon emissions, consumers, businesses, and governments worldwide are now faced with finding solutions to achieve lower energy costs, lower consumption rates of natural and fossil fuels, reduction or elimination of greenhouse gas emissions, and which provide new and renewable energy technologies that will have a lasting positive effect on the earth and its environment.

It is believed that the disclosed devices offer true gains in fuel utility with a corresponding decrease in greenhouse gas emissions and substantially little heat dissipation to atmosphere. Further, it is believed that the disclosed devices provide solutions for the venting of emissions from various combustion processes which utilize fossil fuels. Not only do the disclosed devices seek to reduce the discharge of such pollutants to atmosphere through secondary combustion processes, they can enhance heat recovery by augmenting the primary combustion process with one or more combustion processes, thereby providing for “sequential” combustion processes. In addition, the disclosed devices can provide a more effective means for heat to be transferred to a desired environment or media.

Thermal energy is often mistakenly defined as being a synonym for the word heat. It is acknowledged that an object cannot possess heat, but only energy. Heat is energy or more precisely the process of energy transfer from one kind of matter to another. The term “thermal energy” thus when used in conversation is often not used in a strictly correct sense, but is more likely to be only used as a descriptive word. Where the term “thermal energy” is used herein, the word “heat” is implied.

The disclosed devices seek to improve opportunities to use this heat, not only for heating purposes but for energy production by moderating and/or modifying heat transfer between objects in proximity through the use of a multi-faceted approach to waste heat recovery. By employing diverse materials in conjunction with the structural advances disclosed herein, it is possible to customize systems to take advantage of the inherent properties of these materials and thereby allow and direct the movement of heat to a desired medium and at the same time control heat loss. Applying these technologies, the heat from virtually any source can be routed to wherever it is can be best utilized. In addition, almost any combustible material can be made into a fuel source that is “clean” as compared to the use of the combustible materials without the incorporation of these technologies. By

dramatically increasing the operating efficiency of a heat exchanger, the technology will consequently generate a higher rate of conversion. This can result in use of less fuel, which can lead to less pollution and a decrease in system operating costs. As operating costs decrease, higher rates of energy conversion can translate into increased output.

Thus, there is a great need for more effective products which provide higher efficiency in power generation, waste heat recovery, and incineration applications. The improvements in thermal energy transfer and utilization which are disclosed herein, have a bearing on the heat exchange process of a transfer system, and potentially have wide application in various industry sectors. The disclosed devices present improvements in the area of heat exchange products and applications that can provide superior methods of thermal energy collection and transfer. The disclosed devices can also provide drastic reduction or elimination of emissions from combustion devices utilizing the technology.

It is contemplated that the disclosed devices can be used in conjunction with primary sources of energy such as fossil fuels, nuclear fuels and fuels from renewable sources such as the sun, wind, earth (geothermal), water (hydraulic/hydro), and the oceans (tides, waves, or ocean-temperature energy conversion). A solar energy system could benefit in that thermal energy may be focused or directed to a desired location or medium. A nuclear power plant could utilize the full potential of its fuel source and could conceivably reduce or eliminate the volume of its waste. Mechanisms, such as engines, could be manufactured to be a fraction of their original size. By better utilizing the energy produced, such devices could have superior performance over their larger predecessors. With the disclosed technology, it is also contemplated that an overall reduction of hydrocarbon emissions and dissipative heat could take place.

The disclosed devices have application in the areas of industrial incineration, power boilers, water heaters, residential and commercial solid fuel waste heat recovery appliances, and electric power generation. In addition, the technology could have application in the areas of solar systems, desalination systems, aircraft and vehicular engines, electric motors, turbines, oil pans on internal combustion engines, transmission cooling pans, cooling navigational and electronic systems, and computer cooling and power supply. Ecological applications could include agricultural crop heat, heat drying of grain elevators, cooling towers, power plants, military uses, remediation and hazardous materials cleanup among others. The disclosed technology would be easily adapted with all forms of fin type thermal dissipation heat exchangers.

SUMMARY OF THE DISCLOSURE

The disclosed devices seek to effect heat transfer to be employed for one or more uses or to one or more media. In addition, the disclosed devices seek to reduce the discharge of pollutants from primary combustion processes by implementing secondary combustion processes. With more effective heat capture and utilization, the disclosed heat exchange technologies provide methods and apparatus to reduce heat dissipation to atmosphere.

Disclosed is a heat recovery unit capable of being integrated in a combustion device, the apparatus comprising: a plurality of conductive fins mounted substantially horizontal in a wall of an inner space or acutely angled therefrom; one or more opposing conductive fins mounted in spaced and stepped opposition of each of the plurality of fins; an interior end of each of the fins being positioned in the inner space and capable of being exposed to an exhaust stream; a distal end of each of the fins terminating at a position exterior to the inner space. A connecting plate connects at least two of the distal ends. As the exhaust stream contacts the interior ends, it is directed through the inner space in a path as bounded by the interior ends. A portion of heat of the exhaust stream is transferred by the fins to a medium in communication with the distal ends. Heat transferable to the connecting plates can be routed to one or more uses or media. A front and a back end of each of the fins terminate at a position exterior to the inner space. In addition, a locking means secures the interior ends in the inner space. The fins further comprise materials that are dissimilar from the material used to enclose the inner space.

A heat recovery unit installable in a stack of a combustion unit comprises: one or more conductive fins mounted substantially perpendicular to a wall of an inner space or acutely angled therefrom; each of the one or more fins in spaced and stepped opposition with an opposing conductive fin mounted substantially horizontal therewith or acutely angled therefrom; an interior end of the fins being positioned in the inner space and capable of being

exposed to an exhaust stream from a chamber of the combustion unit; a distal end of said fins terminating at a position exterior to said inner space. This embodiment further comprises a conductive plate mounted substantially transverse the inner space and over an inlet for the exhaust stream, the ends of the plate terminating at a position exterior to the inner space and extendable through one or more media. As the exhaust stream contacts an aperture in the

plate, it is directed through the inner space in a path as bounded by the interior fin ends. A portion of heat of the exhaust stream is transferred by the fins to a medium in communication with the distal end of the fins; and a portion of heat of the exhaust stream is transferred by the plate to a medium in communication with the ends of the plate. A front and a back end of each of said fins terminate at a position exterior to said inner space. In addition, a locking means secures the interior ends of the fins in said inner space. Locking means also can secure the plate in the inner space. The fins and/or plate comprise materials that are dissimilar from the material used to enclose the inner space. One or more optional fins are mountable in the stack, the chamber or a hood of the combustion unit to transfer a portion of heat from the chamber to a medium in communication with a distal end of the optional fins.

Disclosed is a device comprising: one or more conductive plates mounted substantially transverse an inner space and over an inlet for an exhaust stream from a primary combustion unit, each of the plates further comprise a first end and a second end terminating at a position exterior to the inner space and extendable through one or more media. The exhaust stream enters an aperture in the one or more plates and is directed through the inner space; and a portion of heat of the exhaust stream is transferred by the one or more plates to a medium in communication with the first and second ends of the plate. The second ends further comprise a front edge and a back edge, each of the edges extendable through one or more media. One or more conductive fins can be mounted substantially horizontal to the one or more plates or acutely angled therefrom, each of the one or more fins in spaced and stepped opposition with an opposing conductive fin mounted substantially horizontal thereto or acutely angled therefrom. In this embodiment, the aperture can be offset from the center of its respective plate. In addition, the device could further comprise a core capable of housing a heat source or medium, the core mounted in spaced relation to an adjacent pair of plates. The core could be houseable in the inner space or extendable therefrom. One or more optional fins are mountable in a stack, a chamber, or a hood of the primary combustion unit to transfer a portion of heat from the chamber to a medium in communication with a distal end of the optional fins.

According to the disclosed devices, a medium in communication with the first and second ends of a plate can also be in communication with an adjacent or a distant plate. Further, the distant plate may reside in another heat recovery unit; one or more plates could be in common with another heat recovery unit. To enable further combustion or secondary combustion, one or more catalytic devices can be mounted in or adjacent to the aperture of the one or more plates.

Also disclosed is a heat recovery unit comprising: one or more conductive plates mounted substantially transverse an inner space, a first end and second end of each of the plates terminating at a position exterior to the inner space and extendable through one or more media; one or more cores capable of housing a heat-carrying medium or an atomic heat source, at least one of the cores positioned to transfer heat of the medium or the atomic heat source to one of the plates; and wherein a portion of said heat is transferred by the one or more plates to a medium in communication with each of the first and second ends. Each of the second ends may further comprise a front edge and a back edge, each of the edges extendable through one or more media. In addition, the heat-carrying medium or the atomic heat source can pass through an aperture of one of the plates, thereby providing for a longitudinally positioned core.

Another embodiment of the disclosed devices involves a system comprising: a plurality of combustion devices configured in series, parallel, and/or grid format to form a family or a gang of devices; each of the plurality of combustion devices equipped with a heat exchanger comprising one or more conductive plates mounted substantially transverse an inner space and over an inlet for an exhaust stream, the one or more plates having two ends terminating at a position exterior to said inner space. The exhaust stream is directed through the inner space to make contact with the one or more plates. A portion of heat of the exhaust stream is transferred by the one or more plates to a medium in communication with the ends. The medium can be housed in a core of a heat exchanger that is capable of making a long distance transfer of heat. The medium can be in communication with an end of an adjacent or a distant plate. In addition, one of the one or more plates can be shared by some or all of the plurality of heat exchangers.

Also disclosed is a method comprising the steps of: combining a heat recovery unit with one or more combustion devices, the heat recovery unit comprises one or more conductive plates which extend outwardly from a hollow core. The core is capable of receiving and housing a portion of a heat-carrying medium. The method further comprises the step of contacting the one or more plates with the heat-carrying medium and routing heat from the heat-carrying medium to one or more uses or media by means of the one or more plates.

Another heat exchanger embodiment discloses: one or more conductive plates comprising ribs which extend radially from a hollow core. The core is capable of housing a heat source. A portion of heat from the heat source is transferred via the ribs to a medium in communication with an outermost edge of the one or more plates.

In another embodiment, a heat exchanger comprises: one or more conductive plates having ribs which extend outwardly from a hollow or solid core, the core being capable of receiving and housing heat transferred by the ribs from an outermost edge of the plate. A portion of heat is transferred in the core to one or more uses or mediums in communication with the core. The outwardly extending ribs can be radial. Entropy controls may be utilized to prevent undesired heat loss and to pull heat back to the core. In accordance with this device, a plurality of heat exchangers can be connected in series to form an extended core to provide for a long distance transfer of heat.

In yet another embodiment, a heat exchanger comprises one or more conductive plates which extend outwardly from a hollow core. The core is capable of receiving and housing heat transferred from an outermost edge of the one or more plates. The outermost edge of the plate can receive heat from a solar source or a geothermal source. A portion of the heat is transferred in the core to one or more uses or mediums in communication with the core.

In another embodiment, a heat exchanger comprises one or more conductive plates which extend outwardly from a hollow core, the core being capable of receiving and housing a portion of heat transferred from an exhaust stream. The exhaust stream contacts an aperture in the one or more plates and is directed through the core to an exit. A portion of heat of the exhaust stream is transferred by the one or more plates to a medium in communication with an end of the one or more plates. The medium is capable of being routed to a distant space for heating purposes.

In yet another embodiment, a heat exchanger comprises a plurality of conductive plates mounted substantially perpendicular with a housing, each of the plates having a first and a second end. The first and second ends extend through a respective surface of said housing. A first connecting plate connects at least two of the first ends and is mountable adjacent a heat source and separated from the heat source by an adjustable distance. A second connecting plate connects at least two of said second ends. The second connecting plate is exposed to a cooling medium. A portion of heat from the heat source can be transferred from the first connecting plate to the second connecting plate. Heat transferred to the second plate can be routed to one or more uses or media. In addition, heat transferred can be controlled by adjusting the distance. The various distances may also be adjusted independently.

The disclosed devices also provide for an apparatus adapted for use with an electric power generating device. The apparatus comprises a heat recovery unit having one or more conductive plates mounted substantially transverse an inner space and over an inlet for a heat-carrying medium. A perimeter of the plates terminates at a position exterior to the inner space. The heat-carrying medium contacts apertures in the one or more plates and can be directed through the inner space in a path as regulated by the apertures to be routed to one or more power utilities. A portion of available heat is transferred to a medium in communication with the perimeter by means of the one or more plates. For example, the available heat can be used to heat a boiler medium whereby electric power can be generated. The apparatus can further comprise transport means to enable the device to be moved. Specifically, a mobile apparatus can comprise a carbonaceous feedstock and a combustion unit mounted in a respective rail car of a train system. The carbonaceous feedstock is capable of being burned in the combustion unit to generate a heat-carrying exhaust stream. The combustion unit comprises a heat recovery unit having one or more conductive plates mounted substantially transverse an inner space and over an inlet for the heat-carrying exhaust stream. A perimeter of the plates terminates at a position exterior to inner space. The heat-carrying exhaust stream contacts apertures in the one or more plates and can be directed through the inner space in a path as regulated by the apertures to be routed for electric power uses. A portion of available heat is transferred to a medium in communication with the perimeter by means of the one or more plates. Available heat can be used to heat a boiler medium whereby additional electric power can be generated.

A method comprises the steps of: combining one or more combustion devices, wherein at least one of the combustion devices comprises one or more conductive plates mounted substantially transverse an inner space and having a perimeter which terminates at a position exterior to the inner space; contacting apertures in the one or more plates with the heat-carrying medium to be directed through the inner space in a path as regulated by the apertures; routing the heat-carrying medium to one or more power utilities; transferring a portion of available heat to a medium in communication with the perimeter by means of the one or more plates. The available heat can be used to heat a boiler medium whereby electric power can be generated.

Also disclosed is a power generating apparatus comprising a compressor capable of generating a heat-carrying compressed gas medium and a heat recovery unit having one or more conductive plates mounted substantially transverse an inner space to receive heat from the heat-carrying compressed gas medium. The heat can be transferred to a perimeter of the plates to be used to heat a boiler medium whereby electric power can be generated and whereby the gas medium can be cooled. A condenser condenses the gas medium into a pressurized liquid; and an expansion valve expands and evaporates the liquid medium to be used for cooling an adjacent enclosed space.

Yet another embodiment discloses a method comprising the steps of: mounting one or more conductive plates in a heat recovery device, each of the plates extending outwardly from an inner space housing a heat-carrying medium. Each of the plates comprises distal ends in communication with a terminus medium. The method further comprises the step of contacting the one or more plates with the heat-carrying medium and routing a portion of available heat from the heat-carrying medium to the terminus medium by means of the one or more plates. In addition, the method can comprise the step of connecting a distal end of at least two of the one or more plates to adjust a temperature of the terminus medium.

These and other advantages of the disclosed device will appear from the following description and/or appended claims, reference being made to the accompanying drawings that form a part of this specification wherein like reference characters designate corresponding parts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A to IF depict various embodiments of a heat transfer device disclosed herein.

FIGS. 2A, 2B illustrate various finned plate embodiments.

FIGS. 3A to 3C illustrate retrofitted devices utilizing one embodiment of the disclosed device.

FIGS. 4A, 4B each show the implementation of an embodiment of the disclosed device.

FIGS. 5A, 5B present overall illustrations of how media can be interrelated with respect to the disclosed device.

FIGS. 6A, 6B depict how the disclosed devices can be tied into each other to form a collective system or gang of devices.

FIG. 7A depicts an embodiment of the disclosed device adapted for use with an internal combustion engine.

FIGS. 7B, 7C depict embodiments of the disclosed device adapted for use with a cooling pan.

FIGS. 8A, 8B show embodiments of the disclosed device capable of transferring heat from and/or to a central core.

FIG. 9A depicts an embodiment of the disclosed device adapted for long distance or long 10 range heat transport.

FIGS. 9B, 9C depict how the embodiment shown in FIG. 9A can be adapted from use with a collective system or gang of devices.

FIGS. 10A, 10B show embodiments of the disclosed device adapted for use with solar heat.

FIG. 11 shows an embodiment of the disclosed device adapted for use with geothermal energy.

FIGS. 12A, 12B, 12C show examples of how the disclosed devices can be adapted into a system of conventional devices.

Before explaining the disclosed embodiments of the disclosed device in detail, it is to be understood that the device is not limited in its application to the details of the particular arrangements shown, since the device is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.

DESCRIPTION OF THE DISCLOSED EMBODIMENTS

The following description is provided to enable any person skilled in the art to make and use the disclosed apparatus. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present apparatus have been defined herein specifically to provide for a multi-faceted approach to waste heat recovery and utilization. Furthermore, implementation of the disclosed devices and methods will necessarily be determined through engineering and technically sound design decisions to meet the goal(s) to be achieved. Thus, an acceptable design or problem solution is likely to be based on many different criteria, which might include thermodynamic performance, available technology, material selection, and economics. Not only should an energy analysis be performed, a thermodynamic assessment of each system or systems would be incomplete without a second-law analysis. It is to be understood that in some cases the system boundary may be viewed as a closed system while in other cases the thermodynamic system may be an open system.

Waste heat refers to heat produced by machines and industrial processes for which no useful application is found and is typically regarded as a waste byproduct. As stated above, throughout history engineers have attempted to understand and control the flow of heat through the use of thermal insulation, heat exchangers, and other devices. It is well known that waste heat is necessarily generated and has been commonly accepted as the norm. For example, the simple burning of a natural fuel such as wood in a residential wood burning stove can create a large amount of waste thermal energy which is discharged from its chimney stack. Attempts may have been made to capture the waste heat and reuse it. However, it is probable that these attempts have only minimally increased the efficiency of the system.

The disclosed devices, on the other hand, seek to take advantage of waste heat which is discharged from combustion based processes that utilize carbonaceous fuel sources and to lower fuel use and emissions. As will be seen below, the disclosed devices can be incorporated into the stacks of new and existing systems to capture and direct waste heat to optimize the system with very effective results. The disclosed devices are not limited to devices having a chimney stack as they can be integrated into conventional systems of energy production devices. The disclosed devices also contemplate the use of nuclear fuels and renewable energy sources. In addition, one having skill in the art would understand that modifications of the apparatus and methods disclosed herein for the purpose of transferring heat from low-temperature bodies to higher temperature bodies could be achieved and still fall within the scope of the disclosure.

FIGS. 1A-1F depict various embodiments of a heat transfer device. Some of the embodiments comprise what is referred to herein as fins, some of the embodiments comprise what is referred to herein as finned plates, and some of the embodiments comprise a combination of fin and finned plates. One of the functions of a fin and a finned plate is to collect and conduct thermal energy from an origin to a terminus.

In FIG. 1A is shown a perspective view of a unit comprising four walls (front 10, back 20 and two sides 30, 40) and having a series of thermally conductive fins A horizontally positioned in a staggered or alternating arrangement above a primary combustion core inlet, I_(A). For reasons discussed below, the walls would employ relatively low thermal conductivity materials. The fins disclosed herein could be substantially perpendicular or angled relative to the surface of a unit's side walls; however, it is believed that the inner portion of the fins should be mounted substantially perpendicular to the direction of gas flow. The idea is to create a structure that exposes the maximum surface area of the fin material to the exhaust stream. The stepped arrangement provides an increase of heating surface over the arrangement without substantially impeding the flow of gases. The dotted lines and arrows shown herein are used mainly to illustrate the concept that the exhaust stream is making contact with the surface area of the fins and finned plates and may not fully represent the actual conditions in place.

The A series of fins are mounted in receiving slots S in unit 100 and jut from side walls 30, 40 in a substantially perpendicular fashion relative to the outer surface of side walls 30, 40. In application, a fin is inserted in a receiving slot S in side wall 30. See for example fin A₁. An opposing fin is inserted in a receiving slot S in side wall 40. See for example fin A₂. If this were a conventional prior art fin, the outer front surface 50 of a fin A would be substantially flush with the outer surface of the front wall 10 and the outer back surface 60 of a fin A would be substantially flush with the outer surface of the back wall 20. In some cases, the fin profile would be shortened in one or more directions x, y, z, or directions (−) (x, y, z) as referenced in FIG. 2A.

Generally heat would be transferred to the terminus of a fin as defined by the dimensions of the protruding fin. The rate of heat flow from one side of an object to the other (or between objects that touch) depends on the cross-sectional area of flow, the conductivity of the material and the temperature difference between the two surfaces or objects. The heat transfer rate by conduction can thus be expressed as

$q = {{kA}\frac{\Delta \; T}{L}}$

where L is the conductor thickness (or length), k is thermal conductivity, ΔT is the temperature difference between side 1 and side 2, and A is the area of the body. As long as there is a temperature gradient across a system boundary, e.g., one degree differential, heat transfer is supported. The disclosed devices seek to apply the principles of conductance and differential temperatures to the disclosed apparatus and their media so as to optimize the opportunities to recover and make beneficial use of waste heat. For example, if a fin originates in the primary medium M₁ having temperature T₁ and extends into a medium or environment M₂ immediately adjacent the fin having temperature T₂ wherein T₂<T₁ but no further, the fin is said to terminate in medium M₂. If a finned plate originates in the primary medium M₁ having temperature T₁ and extends beyond medium M₂ that is immediately adjacent the finned plate and into a third medium M₃ having temperature T₃ wherein T₃<T₁, the finned plate is said to terminate in medium M₃. See also FIGS. 5A, 5B which depict media separated by a solid wall so that they never mix as well as media which are in direct contact with each other.

In a conventional prior art fin, front surface 50 and back surface 60 would be flush with walls 10, 20 (or have a shortened fin profile). Heat would thus be transferred away from slot S to the fin's perimetric edges which are located directly to the right and the left of the heat exchanger apparatus. The fin of the disclosed apparatus, however, extends outwardly from the front and back walls. Thus, front surface 50 can extend in the z direction and back surface 60 can extend in the (−) z direction. Such a fin profile differs from conventional fins that are known in the art and are more akin to the “finned plates” which are discussed more fully below. The finned plates that are disclosed herein can be lengthened in one or more directions x, y, z or directions (−) (x, y, z).

Receiving slot S extends into front wall 10 and/or back wall 20 by a distance S_(X) to allow the A series of fins to protrude the appropriate distance frontwardly and/or rearwardly. In short, the profile of the disclosed fins can be lengthened in directions z and/or (−) z as illustrated by fins A₁, A₂. Because the disclosed fins may extend outwardly from walls 10, 20 thereby providing for a larger fin volume, heat can be transferred not only to the perimetric edges located directly to the right and the left of the heat exchanger apparatus, but also to those located in front and behind the apparatus. Thus, heat may be transferred to environments in front of or rearward of a unit due to the increased surface area of the disclosed fin. It will be apparent to one of ordinary skill in the art from this disclosure the length of S_(X) as measured from respective walls 30, 40 that is necessary to achieve the goal for which the disclosed devices are implemented.

As stated above, the A series of fins are mounted in receiving slots S in walls 30, 40 of the disclosed device. The material, thickness, or stiffness of the fins disclosed herein, as well as that of the finned plates, should be adequate to provide a dimensionally stable structure that can be reliably brazed or otherwise fastened to the system's walls to seal the system boundaries. In discussing the disclosed fins, it is contemplated that the same would apply to the finned plates unless otherwise noted. Therefore where applicable, the fins and/or finned plates will be referred to as “fin devices”.

Distance S_(X) of slot S serves as a locking mechanism for a fin device. Due to its substantially rigid nature, a fin device can be mounted in a receiving slot S a distance S_(X) and then press fit in place. Not only can the press fit hold a fin device in place, it serves as a sealing means to segregate the media environments. For ease of manufacturing and installation, a plurality of fins can first be inserted in respective receiving slots S in side wall 30 wherein the plurality is press fit in place. An opposing plurality of fins can be inserted in respective receiving slots S in side wall 40. The plurality of opposing fins can then be press fit in place to complete the construction of the disclosed device.

A slot S could be of the same width as the thickness of a fin device. Alternately, slot widths and thicknesses of a fin device could be varied as any materials selected may expand and contract with temperature. Flanges or other sealing means including press fits could be utilized so as to prevent leakage or undesired losses of heat at the system boundary. In other words, the contact points along slot S should be sealed to ensure a discrete boundary wall between the unit's side wall and the fin device. A tongue and groove engagement and a soldered joint provide an alternate method of application. Metals and materials can vary in thickness, expansion rates, etc. at various temperature and pressure parameters. It will be apparent to one of ordinary skill in the art from this disclosure the types of sealing, e.g., press fits, welds, sealants, etc. to be utilized to ensure the suitable sealing means.

Different materials or media have varying abilities to conduct heat. Some materials are said to conduct heat poorly, i.e., wood, Styrofoam®, etc., while others are said to conduct heat well, i.e., metals, glass, some plastics, etc. It is desirable that the fin devices be thermally conductive and constructed from materials that are dissimilar from the material used in the side walls, and preferably from materials that promote the amount of heat transfer desired. Not only should the heat collecting fin devices have sufficient heat conductivity, it is contemplated that they be sufficiently refractory and resistant to corrosion. It is also conceivable that one or more of the fin devices could be constructed such that they are dissimilar one from another. The fin devices themselves could also be impregnated with dissimilar materials. In addition, the fin devices themselves could have fins to enhance the efficiency of heat conduction.

The fin devices are illustrated herein as being smooth or planar, however, it is contemplated that the surfaces of the fin devices could be non-uniform, corrugated or otherwise varied to promote or enhance turbulence and thereby increase heat transfer. Fin type, dimension, configuration, surface structure, etc. are all factors to be considered. For example, one could choose from any number of known fin types and configurations. One could increase the cross-sectional area of an object to increase its heat transfer rate. Alternately, one could decrease an object's thickness to decrease thermal resistivity. Depending on the goal to be achieved, a fin device could be uniform in thickness throughout its area while in other circumstances a fin device could have varying thicknesses.

The fin devices may also be selected from materials that are known to be catalysts. If one or more of the fin devices were constructed of a ceramic that is coated with a metal catalyst, e.g., platinum, rhodium and/or palladium, the device could facilitate the process of secondary combustion whereby the device removes most or all pollution emissions, i.e., nitrogen oxide emissions, unburned hydrocarbons, carbon monoxide, etc. from the appliance or system. It is also contemplated that the inner walls of the disclosed devices can comprise a medium to allow for heat capture and/or for gas scrubbing. For example, as combustion gases pass through the various embodiments and makes contact with the inner walls, scrubber media can act to scour the gas to ensure a cleansed vented gas.

Embodiment 100 receives combustion gases from a combustion unit (not shown). The A series of fins originate from an inner portion of device 100 and extend outwardly through each of walls 10, 20, 30 or walls 10, 20, 40. Combustion core inlet I_(A) is offset from fin A₁. Flow from core inlet I_(A) is directed in a substantially serpentine path as bounded by the A series of fins and as shown conceptually by the dotted lines and arrows. Not only do the fins collect and conduct thermal energy, they serve to restrict the flow of combustion gases through a unit and can be used to promote turbulence. In all forms, the fin devices close to the source of heat receive heat from the products of combustion delivered from the combustion unit and/or burner, and conduct heat to the designated medium. In an alternate configuration, core inlet I_(A) could be placed directly under fin A₁ if required by the particular application.

To increase the likelihood that combustible substances are joined with sufficient oxygen to complete combustion, the devices disclosed herein contemplate the injection of excess air and/or the use of catalytic devices to promote combustion. Although not shown, excess air could be introduced at core inlet I_(A) to enhance combustion. Catalytic devices useful for enhancing secondary combustion (or for providing sequential combustion) can be incorporated into any of the disclosed devices. In this embodiment, one or more conduits 150 can be mounted along the surface of front wall 10 or back wall 20 so as not to interfere with the function of fins A₁, A₂. Entry means (not shown) appropriately penetrate wall 10 (or 20) to allow the injection of air. The level of excess air required in a given combustion process is dependent on the type of fuel, the configuration of the combustion chamber, the nature of the fuel firing equipment, and the effectiveness of mixing combustion air with the fuel. Since excess air serves to dilute and thereby reduce the temperature of the products of combustion, thereby reducing heat energy available for useful work, the actual excess air used in the combustion process is a balance between the desire to achieve complete combustion and the need to maximize the heat energy available for useful work. It will be apparent to one of ordinary skill in the art from this disclosure the configuration for implementing excess air, the amount of excess air, and the type and location of catalytic devices necessary to achieve the goal for which the disclosed devices are implemented.

In the FIG. 1A embodiment, the placement of the A series of fins could conceivably allow a stream of exhaust gas to rise vertically up the stack with substantially no obstruction. In other words, there could be a vertical pathway formed adjacent to the internal end of the staggered fins. This may be useful in preventing clogging problems. In addition, a vertical pathway may facilitate cleaning of the unit. For example, a swab may be inserted into the device's vent. In some cases it may be desirable to overlap the staggered fins to cause a more dramatic meandering of exhaust gas through the heat exchanger. It is to be understood that such designs, however, could result in sooting and/or lead to other buildup problems.

For fluid systems (either liquid or gases), the pressure on the wall of a container holding the fluid is due to the cumulative effect of individual molecules striking the walls of the container, causing a normal force on the surface. Each fin device therefore should be mounted substantially perpendicular to the flow to potentially increase the amount of normal force acting on each surface. In operation, a stream of combustion gas from core inlet I_(A) strikes the fin device and is thrown outwardly in all directions with a whirling motion into the passing combustion gas, producing a condition of turbulence. Some of the gas flows to the edges and corner areas adjacent the system boundary between the walls and the fin devices. It is contemplated that a sheet-type fin device would provide the most effective surfaces for receiving gas flow (or impacts); however, tubular or cylindrical fin devices could also be used.

The volume or region, which is created by the unit's four walls and the stepped arrangement of the fin devices, forms a substantially discrete thermodynamic system. Thus, one unit may comprise a number of system boundaries as bounded by the appropriate wall sections of the unit walls and portions of the relevant upper and lower fin device. As shown in the 1A embodiment, there could be five discrete systems, each potentially providing for a discrete combustion area. While the stepped arrangement does not substantially impede the flow of gases, these systems can serve to increase the dwell time of the gas therein. Although the manner in which the disclosed device effectively creates eddy currents may not be fully understood at this time, it is surmised that gas flowing to the edges and corner areas of these volumes is being momentarily entrapped adjacent the fin as combustion gases pass by. Eddies occur at the bottom and top surfaces of the fins. The entrapped gas swirls as a reverse current is created by the combustion gas flowing past. The molecules in the hot gas of the system move fast so that they collide more rapidly and with more force against each other and the surface of the fin. This motion causes the molecules to push each other farther apart against the walls of the system volume, compressing the gas.

Gradients in chemical potential tend to cause substances to be transferred from one phase to another. At the surface of a fin device, conduction occurs as rapidly moving or vibrating atoms and molecules of the waste heat interact with the neighboring atoms and molecules of the fin device, transferring some of the energy as heat to these neighboring atoms. As temperature increases in the system, molecular activity increases. Since the disclosed technology contemplates the use of dissimilar materials having high thermal conductivity (such as metals), the forward transport of energy would increase as temperature increases. The system's environment could also encourage combustion as it would be accelerated by the heat which is reflected on to the gas stream from the surrounding fin devices. The eddies could be beneficially ignited. It is surmised that an angling of the fins could alter the turbulent flow patterns which may exist in the fluid chamber.

In the embodiment of FIG. 1A, three media are involved. As flow from core inlet I_(A) comes into contact with the surface of a fin device, heat is transferred from a primary medium (internal portion of the heat exchanger unit) to the fin device (second medium) at the system boundary between the gas and the fin device. From thence, heat is transferred from the fin device to a third medium at the system boundary between the fin device and that medium.

For the remainder of the discussion, it is assumed that the center of the fin device will have the same temperature as that of the primary medium (internal portion of the heat exchanger unit) or core. Thus, the fin device itself can be referred to herein as the primary medium. Because a fin device can extend into one or more media, heat can be dissipated in the one or more media—namely a second medium, a third medium, and so forth. With the technology disclosed herein, heat transfer can be controlled by engineering the location of the terminus of a fin device. Additional discussion about system media is set forth below.

Plates 160 provide for the connecting of the outer ends of one or more of the A series of fins to form a modified fin A′. Although not shown, a similar plate could reside in the interior of device 100 to connect the internal ends of one or more of the A fins. The inner plate (not shown) could provide a larger surface area by which heat may be transferred. As stated above, energy is dissipated at the terminus of a fin device. If the heat exchanger unit with its modified fins A′ is bathed in a cooling media within an outer sheath (a medium M₂), energy can be dissipated at a greater rate. One or more knock out holes (discussed below) could be positioned in the fin devices to direct or enhance the flow of gas. The connecting plates could also be non-uniform, corrugated or otherwise varied to provide turbulence and thereby increase heat transfer. A cooling medium passes through a hollow modified fin A′ by means of feed line 170. A conduit 180 serves to deliver the resulting heat-carrying medium to other uses or media. As shown, the disclosed device can be used to transfer heat from a first medium M₁ to some third medium M₃.

As an example of the utility of the 1A embodiment, unit 100 could be installed as a replacement of a section of the flue pipe of an existing residential wood, coal, or pellet burning stove. Thus, the device could be offered as a retrofit for an existing unit. As will be later shown, the devices disclosed herein can also be integrated into a newly designed product or system of products with a particular application in mind. These devices could also comprise an integrated side arm that could be used for purposes such as boiling water for potable and non-potable uses.

In FIG. 1B is shown a perspective view of a four walled unit 200 having a series of thermally conductive fins B mounted horizontally in a staggered or alternating arrangement. It is important to note that although the disclosed devices are illustrated to be square or rectangular in shape, other configurations are possible, i.e., cylinders, cones, pyramids, etc.

A monolithic plate-like structure P_(B) having an aperture 250 stratifies or bridges the width of a primary combustion core and core inlet I_(B). Aperture 250 is illustrated here as being centrally aligned, however, it could be placed offset to any side in the finned plate if required by the particular application. Plate P_(B) resembles a fin but differs in that it is elongated in length and width and is conceptually continuous, thereby facilitating its ability to originate in a first medium M₁ and extend into one or more media, M₂ to M_(n), thereby transferring heat to the terminus environment of the fin device wherever that terminus is. This device is referred to as a finned plate and not only extends outwardly in a right to left configuration from a unit's side walls, it may also extend outwardly in a front to back configuration from a unit's front and back walls, respectively (see FIGS. 2A, 2B ). The monolithic and expansive construction of the finned plate facilitates continuous heat transfer until the finned plate terminates.

The monolithic and expansive construction of the finned plate also facilitates mounting of catalytic devices useful for enhancing secondary combustion or providing sequential combustion at the finned plates. It is contemplated that a catalytic device could be molded directly into the aperture of a finned plate or mounted adjacent thereto by means of brackets, housings, etc.

As stated above, the profile of the disclosed fins can be lengthened in directions z and/or (−) z. That of the finned plates can be lengthened in one or more directions x, y, z or directions (−) (x, y, z). In embodiment 200, plate P_(B) extends outwardly in a right to left configuration from side walls 30, 40. Outer front surface 55 of finned plate P_(B) is shown to be substantially flush with the inner surface of the front wall 10. Correspondingly, the outer back surface of the finned plate would be substantially flush with the inner surface of the back wall 20.

The B series of fins originate from an inner portion of device 200 and extend outwardly through each of walls 10, 20, 30 or walls 10, 20, 40. The fins are mounted in receiving slots S in the side walls of unit 200. The B series of fins jut from side walls 30, 40 in a substantially perpendicular fashion relative to the outer surface of side walls 30, 40. The outer front surfaces 50, 60 of the B series of fins extend outwardly from walls 10, 20 by means of a receiving slot of distance S_(X) to allow heat to be transferred to environments in front of or rearward of unit 200. It will be apparent to one of ordinary skill in the art from this disclosure the length of S_(X) as measured from respective walls 30, 40 necessary to achieve the goal for which the disclosed devices are implemented. A connecting plate similar to plate 160 of device 100 could be used to connect the outer and/or inner ends of the one or more of the B fins if desired.

Like the embodiment of FIG. 1A, combustion gases from a combustion unit (not shown) pass through a combustion core inlet. Combustion core inlet I_(B) in FIG. 1B is centrally aligned such that combustion gases flow through unit 200 substantially as shown by the dotted lines and arrows. Finned plate P_(B) which transverses core inlet I_(B) collects or extracts thermal energy from the primary combustion core via aperture 250. A portion of heat from the exhaust stream can be transferred continuously along the pathway provided by finned plate P_(B) until that pathway is disconnected or interrupted, each finned plate operating as a delivery system for thermal energy. Viewed as a whole, a finned plate could conceivably transfer heat in any desired direction depending on the product or application desired. Because finned plate P_(B) terminates in this illustration, energy is dissipated to the terminus environment. Because the finned plates disclosed herein may be designed with other media in mind, it is conceivable that a finned plate may be used to collect and conduct thermal energy until it terminates in a second, third, fourth, etc. adjacent medium or in connection with another unit or system M_(n). Some illustrations are set forth below.

A fin device could be solid or it could have a hollow core. Alternately, a fin device could be half hollow. The other half could comprise solid tubes. It will be apparent to one of ordinary skill in the art from this disclosure the suitable fin and/or finned plate design necessary to achieve the goal for which the disclosed devices are implemented. In some cases, the fin devices may be engineered with a gradient which diminishes from one location to another. It is contemplated that with the use of the knockout holes (discussed below) to enable gas flow and turbulence and the apertures to allow heat to enter and pass through a fin device, thermal energy may transferred to intended media in accordance with second law thermodynamics. See also FIG. 5A.

The B series of fins should be positioned in relation to the source such that a maximum fin surface area can be exposed to the exhaust stream. For example, the B series of fins could be mounted substantially perpendicular to gas flow. It is contemplated that the fin devices that are closest to the heat source can receive a maximum heat from the products of combustion delivered from the burner and readily conduct heat to the terminus environments. Therefore, the surface area of the lower fins could be larger than that of the uppermost fins. The fins also serve to restrict or direct the flow of combustion gases through the unit. It will be apparent to one of ordinary skill in the art from this disclosure the fin design necessary to achieve the goal for which the disclosed devices are implemented. Excess air could be introduced at core inlet I_(B) or at aperture 250 to enhance combustion. In this embodiment, a conduit 150 delivering excess air can be mounted along the surface of front wall 10 so that it does not interfere with the function of finned plate P_(B). Entry means can appropriately penetrate wall 10 or 20 to allow the injection of air to finned plate P_(B). Catalytic device(s) can be mounted at finned plate P_(B) or at one or more of the B fins to promote combustion.

FIG. 2A depicts a top perspective view of a device having rectangular finned plates. To facilitate the use of the finned plate as a continuous pathway to and through multiple media as described herein, it is desirable to construct the finned plate as a one-piece unit. In application, an insertable end 5 of a finned plate PB₂ is inserted in a receiving slot S in side wall 30 and through a receiving slot S in side wall 40 whereby insertable end 5 protrudes therethrough somewhat like a conventional fin. An inner section 7 of finned plate PB₂ is mounted substantially transverse inner space housing medium M₁ to overlie core opening I_(B). An outer front surface of finned plate PB₂ is thus substantially flush with the inner surface of the front wall 10. Correspondingly, the outer back surface of finned plate PB₂ would be substantially flush with the inner surface of the back wall 20. Distance S_(X2) of slot S serves as a locking mechanism for finned plate PB₂ which can be press fit in place. The noninsertable end 6 of finned plate PB₂ juts from walls 10, 20, 30 in a substantially perpendicular fashion relative to the outer surface of wall 10, 20, 30.

An insertable end 5 of an opposing finned plate PB₁ is inserted in a receiving slot S in side wall 40 and through a receiving slot S in side wall 30 whereby insertable end 5 protrudes therethrough somewhat like a conventional fin. An inner section 7 of finned plate PB₁ is mounted substantially transverse inner space housing medium M₁ to overlie core opening I_(B). Distance S_(X1) of slot S serves as a locking mechanism for finned plate PB₁ which can be press fit in place. The noninsertable end 6 of finned plate PB₁ juts from walls 10, 20, 40 in a substantially perpendicular fashion relative to the outer surface of walls 10, 20, 40. The series of finned plates can have substantially similar dimensions. This is done for ease of manufacturing and installation so that substantially uniform plates can be easily stamped or otherwise produced and/or stored. It is contemplated however, that a finned plate could be custom built to extend in directions x, y, z or directions (−) (x, y, z) to encapsulate the combustion core unit yet maintain the monolithic construction of the finned plate if desired. In embodiment 300A, the width of slots S is substantially the same as the thickness of finned plates PB₁ and PB₂.

It can be seen that a finned plate can comprise one or more knockout holes 70. Although the boundaries are not specifically shown, the knockout holes would each reside in a separate medium, M₂, M₃, etc. In addition, a finned plate could comprise one or more orifices or apertures 250. Not only can a knockout hole or aperture provide entry to the finned plate so the plate can become a thermal energy pathway, each can also provide a means to encourage gas movement. It will be apparent to one of ordinary skill in the art from this disclosure the suitable placement of knockout holes and/or apertures. For example, in finned plate PB₁ a knockout hole 70 could be positioned to the left of the aperture 250 to allow heat passage to the upper finned plate P_(B2). In the upper finned plate P_(B2) a knockout hole 70 could be positioned to the right of the aperture 250. It is generally desirable to place a knockout hole in opposition to an adjacent knockout hole for draft purposes and to aid in combustion. The physical location and engineering of the knockout can be important in relation to the location of a catalytic device, oxygen injector, and other devices that can strategically enhance the dynamics, performance, properties and combustion characteristics of the disclosed device.

Core opening I_(B) and apertures 250 shown in FIG. 2A are round and centered but could be any suitable shape and located as called for by the particular application. For example, core opening I_(B) and aperture 250 shown in FIG. 2B are semi-circular. The one or more orifices or apertures 250 facilitate the transfer of heat from the gas to the finned plate. As an exhaust stream passes through core opening I_(B) and apertures 250 a portion of heat of the exhaust stream is transferred to a medium in communication with the perimeter edges of end 6 and/or end 5 of finned plate PB₁. Likewise, a portion of heat of the exhaust stream is transferred to a medium in communication with the perimeter edges of end 6 and/or end 5 of finned plate PB₂.

In FIG. 2B is shown a rounded or disc-shaped finned plate embodiment 200A. Finned plate P_(B1) is mounted in a receiving slot in the outer wall of a cylindrical unit 15. A disc-shaped finned plate would extend from a cylinder wall in the same manner as a square or rectangular finned plate described above. In addition, the disc-shaped finned plate could also extend in a substantially perpendicular or angled fashion relative to the cylinder wall.

In application, an insertable end 5 of finned plate P_(B1) is inserted in a receiving slot in the cylinder and through a receiving slot in the opposite side whereby insertable end 5 protrudes therethrough somewhat like a conventional fin. An inner section 7 of finned plate P_(B1) is mounted substantially transverse inner space housing medium M₁ to overlie core opening I_(B). Distance S_(S) serves as a locking mechanism for finned plate P_(B1) which can be press fit in place. The noninsertable end 6 of finned plate P_(B1) juts from wall 15 in a substantially perpendicular fashion relative to the outer surface of wall 15.

An opposing finned plate (not shown) would be inserted in a receiving slot in the opposite side whereby the insertable end protrudes therethrough somewhat like a conventional fin. It is contemplated however, that a finned plate could be custom built to extend in a circular fashion to encapsulate the combustion core unit yet maintain the monolithic construction of the finned plate if desired. Heat may be transferred to the terminus of the finned plate as defined by the dimensions of the protruding surface.

It will be apparent to one of ordinary skill in the art from this disclosure that any number of configurations of fin devices is possible and still the result will come within the scope of the disclosure. Using the center of combustion core I_(B) as a benchmark, a finned plate could extend in all directions therefrom and preferably, though not necessarily, in a substantially symmetric manner. A round embodiment could extend in one or more directions, n. Like the fins disclosed herein, a finned plate collects and conducts thermal energy. Because a finned plate can be elongated, it is capable of being used to transfer heat to other units and/or systems connected thereto and to media with which it makes contact or is designed to contact.

To illustrate the utility of a finned plate embodiment, assume the device is installed in a stand-alone furnace used for space heating. See for example FIG. 3A. The device could also be embodied as a retrofit unit atop an existing residential wood burning stove. See for example FIG. 3B. These embodiments depict a device like that disclosed in FIG. 1B having a series of thermally conductive fins B mounted horizontally relative to the unit's side walls and substantially perpendicular to gas flow. The unit accepts waste heat from a primary combustion chamber. The devices disclosed herein can also be integrated into a newly designed product or system of products with a particular application in mind. See for example FIGS. 4A and 4B which depict a device like that disclosed in FIG. 1B that has been integrated into ducting for home heating. A more detailed discussion of these various devices is set forth below.

In FIG. 1C is shown an embodiment 300 comprising walls 10, 20, 30, 40 and a series of thermally conductive fins C₁, C₂, C₃, C₄ mounted horizontally in walls 30, 40. Finned plates P_(C1), P_(C2) and P_(C3) extend beyond walls 30, 40. A finned plate P_(C1) extends across the primary combustion core, the inlet of which is centrally aligned. A discrete stage is formed between finned plates P_(C1) and P_(C2) and between P_(C2) and P_(C3). As shown, there could be two discrete stages having three sub-stages. Each of the two discrete systems potentially provide for a discrete combustion area. With the appropriate catalytic device(s) and/or excess air, sequential combustion can be achieved. In other words, inlet gas through core I_(C)could undergo a combustion process at finned plate P_(C1). Heat capture can occur at finned plates P_(C2), P_(C3) whereby heat can be transferred to its terminus. Inlet gas could also undergo a combustion process at finned plate P_(C2) or in the systems bounded by finned plates P_(C1) and P_(C2) and finned plates P_(C2) and P_(C3). Heat capture can occur at finned plate P_(C3) whereby heat can be transferred to its terminus.

In embodiment 300 flow is directed in a substantially serpentine path until a transfer point is encountered or allowed to occur, the transfer point being a finned plate. Flow from core inlet I_(C) is directed through apertures 350, 360 and 370 in the respective finned plates P_(C1), P_(C2) and P_(C3) whereby heat may be transferred. The finned plates also serve to restrict or direct the flow of combustion gases through the unit. It will be apparent to one of ordinary skill in the art from this disclosure the plate positioning necessary to achieve the goal for which the disclosed devices are implemented.

As referenced above, fins C₁, C₂, C₃, C₄ and finned plates P_(C1), P_(C2), P_(C3) can be selected from materials that are dissimilar from the material used in the unit's walls. For example, the finned plates could be composed of a conductor such as copper while the unit 300 is formed from cold-rolled steel. As conduction occurs, the hot and rapidly moving or vibrating atoms and molecules of the combustion gas in unit 300 interact with neighboring copper atoms and molecules in the finned plates. Although not a traditional siphon (siphons usually allow for liquid to drain from a reservoir by means of hydrostatic pressure without any need for pumping), thermal energy is said to be “siphoned” to beneficial uses inside and outside of the system. It is desirable for the finned plates to transfer the heat as quickly and efficiently as possible. The fins operate similarly but thermal energy transfer is limited by the terminus of the fin. It is important to note that one or more of the fins and finned plates of the disclosed devices may be materially dissimilar one from another depending on the application involved.

This embodiment can be used to illustrate how one or more devices could be tied-in to each other so each singular device can operate discretely, if desired, and yet be part of a system. For example, assume that device 200 as shown in FIG. 1B and device 300 as shown in FIG. 1C are separated by a distance but joined by a continuing finned plate such that P_(B) equals P_(C1). In other words, the right end of P_(B) is connected to the left end of P_(C1). Flow via inlet core I_(B) passes through aperture 250 in finned plate P_(B). A portion of the heat is directed towards fins B₁, B₂, B_(n). Some of the available heat however is transferred via finned plate P_(B)-P_(C1) to unit 300 where it may be combined with available heat from inlet core I_(C) passing through aperture 350. The “siphoned” thermal energy can be transferred continuously along the pathway provided by the thermally conductive finned plate P_(B)-P_(C1) until that pathway is disconnected or interrupted at the terminus of finned plate P_(C1). Because finned plate P_(C1) terminates in this illustration, energy is dissipated to the terminus environment to the right of unit 300. Here, there are three potential pathways in the form of P_(C1), P_(C2) and P_(C3) by which thermal energy may be transferred to some media M_(n), each finned plate operating as a delivery system for heat. Heat may also be transferred continuously along the pathway provided by the thermally conductive finned plate P_(B)-P_(C1) until that pathway is disconnected or interrupted at the terminus of finned plate P_(B), e.g., to the left of unit 200, if so engineered or if dictated by the thermal gradient.

With the multiple-staged embodiments disclosed herein, one single unit could even perform discrete functions. For example, the lower section of a multi-sectioned unit could be used for a particular preheating purpose. When a predetermined temperature is reached for a process such as a turbine, a controller could signal a blower to force thermal energy into the upper section of the multi-sectioned unit or along pathway of the finned plate as desired. To illustrate, the stage formed between finned plates P_(C1) and P_(C2) could be designated a preheat stage while the stage formed between P_(C2) and P_(C3) could be a primary heating stage.

Combustion core inlet I_(C) is substantially centrally aligned allowing heat to be directed toward fins C₁, C₂, C₃ and C₄. Apertures 350, 360 and 370 of finned plates P_(C1), P_(C2) and P_(C3) are also centrally aligned. As combustion gas from core inlet I_(C) comes into contact with a surface of a fin, some of the gas flows to the edges and corner areas adjacent the system boundary between the walls and the fins. Some of the gas also flows to the edges and corner areas adjacent the system boundary between the walls and the finned plates. Gas is momentarily entrapped and compressed. Due to the larger surface area of the finned plate, it is contemplated that gas compression would occur more prevalently. In addition, it is contemplated that thermal “siphoning” from a finned plate can occur more quickly than from a fin because of the finned plate's apertures and the larger surface of the finned plate; heat transfer may occur more readily if dictated by the thermal gradient.

One or more conduits 150, 150A, 150B delivering excess air can be mounted along the surface of wall 10 or wall 20 so that each does not interfere with the function of the finned plates or fins. Entry means can appropriately penetrate wall 10 or 20 to allow the injection of air. Air can be injected at varying pressures, concentrations, etc. if desired. It will be apparent to one of ordinary skill in the art from this disclosure the combustion environment necessary to achieve the goal for which the disclosed devices are implemented. Apertures 350, 360 and 370 could be placed offset to any side in the finned plate if required by the particular application. As discussed below, a manifold may be utilized. Because the uppermost finned plate may be the final stage an heat transfer system, it may be useful to place means to control the final venting of gases. For example, a finned plate can comprise an air pollution control means such as scrubber, fluidized bed, etc. and/or other controls.

FIG. 1D depicts an embodiment that can provide a great level of industrial utility. Instead of the conductive fins of the embodiments shown in FIGS. 1A, 1B and 1C, unit 400 comprises a series of thermally conductive finned plates D positioned horizontally, one above the other. A finned plate D₁ extends across the centrally aligned primary combustion core inlet I_(D). An inner section of each of the D series of finned plates is mounted substantially transverse the core opening I_(D). Discrete stages are formed between finned plates D₁ and D₂, D₂ and D₃, etc.

Flow from core inlet I_(D) is directed through a series of apertures 450, 455, 460, 465, 475 and 485 in the finned plates. Apertures 450, 460 and 475 are offset from the center of finned plates D₁, D₃ and D₅. Apertures 455, 465 and 485 are opposingly offset from the center of finned plates D₂, D₄ and D₆. The placement of the apertures can aid in directing flow through the unit. Flow from core inlet I_(D) is directed in a substantially serpentine path as bounded by the apertures of the D series of finned plates and as shown conceptually by the dotted lines and arrows. One or more knock out holes (not shown) could be utilized to direct or enhance the flow of gas. The D series of finned plates can be selected from materials that are dissimilar from the material used in the side walls and may be materially dissimilar one from another.

As in the cases illustrated above, some of the gases eddy near the edges and corner areas adjacent the system boundary between the walls and the D series of finned plates. Gas that is entrapped can be readily compressed because of the larger surface area of the finned plate and turbulent flow of the fluid. Molecular agitations increase in relation to the larger surface of the disclosed finned plate. The exchanger's performance can also be affected by the addition of fins or corrugations in one or both directions which further increase surface area and may channel fluid flow or further induce turbulence. Due to the placement of multiple finned plates in this particular embodiment, the heat exchanger is thus designed to maximize the surface area of the boundary between the fluids. As stated above, the monolithic and expandable construction of the finned plate facilitates mounting of catalytic devices useful for enhancing secondary combustion at the finned plates. The use of multiple finned plates serves to maximize thermal energy transfer to other media.

A conduit delivering excess air can be mounted along the surface of wall 10 or wall 20 so that it does not interfere with the function of the finned plates. Given that this embodiment comprises a series of finned plates, it may be appropriate to employ a manifold. Entry means (not shown) can appropriately penetrate wall 10 or 20 to allow the injection of air. Air could be injected at varying pressures, concentrations, etc. It will be apparent to one of ordinary skill in the art from this disclosure the combustion environment necessary to achieve the goal for which the disclosed devices are implemented. As one example, a conduit 150 could be mounted adjacent walls 10, 20 to aid combustion adjacent aperture 450. The same or separate conduit could be used to inject excess air at aperture 460. The shaded areas 450, 460, 475 indicate areas in which catalytic devices may be implemented to enhance secondary and/or sequential combustion.

For ease of manufacturing and installation, a plurality of finned plates can be inserted in respective receiving slots S in side wall 30 wherein the plurality is press fit in place. An opposing plurality of finned plates can be inserted in respective receiving slots S in side wall 40 wherein the plurality of opposing fins is press fit in place to complete the construction of the disclosed device. Because of the monolithic and expansive construction of the finned plates, each may be singularly installed if desired.

FIG. 1E provides for an embodiment similar to that shown in FIG. 1D except that each aperture area 560, 570, 580, 590 and 599 has been shaded to indicate that each finned plate in a system can integrate a catalytic device to enhance secondary and/or sequential combustion. In unit 500 a series of thermally conductive finned plates E are shown. Finned plate E₁ extends across the primary combustion core inlet I_(E). An inner section of each of the E series of finned plates is mounted substantially transverse the core opening I_(E). Aperture 550 is centrally aligned as are apertures 560, 570, 580, 590 and 599. Discrete stages are formed between each of the E series of finned plates. Flow from core inlet I_(E) is directed through apertures 550, 560, 570, 580, 590 and 599 in finned plates E₁, E₂, E₃, E₄, E₅ and E₆ in a substantially vertical path as bounded by the apertures and as shown conceptually by the dotted lines and arrows. The E series of finned plates can be selected from materials that are dissimilar from the material used in the side walls and may be materially dissimilar one with another.

Although each finned plate in the series may be equipped with one or more catalytic devices (not shown) and/or oxygen injectors (see conduit 150), in other embodiments such apparatus may be mounted in an alternating or stepped fashion (see for example finned plates E₁, E₃, E₅). Air can be injected at varying pressures, concentrations, etc. It will be apparent to one of ordinary skill in the art from this disclosure the combustion environment necessary to achieve the goal for which the disclosed devices are implemented. The same or separate conduit could be used to inject air at the various apertures. In addition, it may be desirable to utilize a manifold.

In the embodiment of FIG. 1F flow is directed in a substantially vertical pathway through the implementation of a number of finned plates mounted horizontally above a centrally-aligned primary core inlet. In unit 600 a series of thermally conductive finned plates F are used. Finned plate F₁ extends across core inlet I_(F). An inner section of each of the F series of finned plates is mounted substantially transverse the core opening I_(F). Aperture 650 is centrally aligned as are apertures 660, 670, 680, 690 and 699. Flow from core inlet I_(F) is directed through apertures 650, 660, 670, 680, 690 and 699 in respective finned plates F₁, F₂, F₃, F₄, F₅ and F₆. In this embodiment, flow can be augmented with heat from one or more cores 655 capable of housing a heat-carrying medium. As illustrated by the dotted lines, cores 655 could extend beyond walls 10, 20. Alternately, unit 600 could be modified to house the length of cores 655. The F series of finned plates can be selected from materials that are dissimilar from the material used in the unit's walls and may be materially dissimilar one from another.

In an embodiment employing an augmentation core 655, heat can be directed from core inlet I_(F) through aperture 650 of finned plate F₁ and around hollow tube/core 655 so that it may contact the overlying finned plate F₂ (assuming that hollow tube/core 655 sustains a higher temperature region). Heat dissipating from hollow tube/core 655 can also be transferred to finned plate F₂. In this fashion, finned plate F₂ and each subsequent finned plate in the system is capable of collecting and conducting thermal energy until each terminates in a second, third, fourth, etc. medium. It is contemplated that hollow tube/core 655 could allow for the use of a liquid or gas medium.

The design of this embodiment can lend itself to use with atomic fuel sources. In such an alternate configuration, hollow tube/core 655 could house a nuclear rod. Because the rod(s) could be a consistent source of heat depending on the material, one or more of the F series of finned plates having a lower temperature region would invariably create the necessary temperature gradient for heat transfer to occur. In the atomic energy embodiment, the F series of finned plates could be capable of collecting and conducting thermal energy over long distances until each terminates. In another alternate embodiment, the augmentation cores are replaced by a nuclear rod mounted vertically in the apparatus, passing through the centrally-aligned apertures. It is contemplated that the FIG. 1F embodiment can also be implemented in the industrial boiler industry, in applications having stable liquids environments and for electric power generation by means of steam.

It is contemplated that one or more of the finned plates may be physically connected to each other as further described below. In addition, one or more cores can be connected if so engineered.

FIGS. 3A to 3C illustrate the utility of the embodiment of FIG. 1B. It is contemplated that the devices disclosed herein could be used in indoor and outdoor applications for domestic and commercial purposes, e.g. for heating, for cooking, for agricultural/farm purposes as well as for light industrial applications. It is recognized that some heat transfer to the surrounding environment will be primarily through radiation, but the discussions herein will primarily involve conduction.

As shown in FIG. 3A a four-walled heat exchanger 710 is equipped with four fins B in furnace embodiment 700. Finned plate 720 overlies a combustion chamber 730 which may vary in shape and form. To facilitate the ability of core inlet I to receive heat from chamber 730, a blower or fan may be utilized. Though not shown, the blower/fan could be located below or behind the combustion chamber. An induction unit could also be used if suitable for the application. If the heat exchanger embodiment is to be positioned against a wall or structure, it may be desirable to also locate the air moving means adjacent the unit. An ash pullout bin 780 can be placed below chamber 730 for convenience.

Aperture 750 is centrally aligned. Fins B originate from an inner portion of device 710 and extend outwardly through each of walls 30, 40. In some cases, device 710 could be cylindrical. Heat from aperture 750 is directed through device 710 as shown by the dotted lines and arrows. One or more catalytic devices (not shown) and/or oxygen injectors (not shown) can be strategically mounted so as not to interfere with the function of finned plate 720 but to aid in enhancing combustion. A portion of available heat is collected by finned plate 720 and transferred along the pathway until finned plate 720 terminates. In this embodiment, fins B and finned plate 720 terminate in the same medium or the atmosphere 760. Heat transfer between media 760, 770 occurs if there is a temperature gradient at the system boundary.

If finned plate 720 were to extend into another medium, e.g., an adjacent room at a lower temperature M_(n), flow from aperture 750 could be delivered to that medium M_(n). Thus, the fins could be used to conduct heat to medium 760 while the finned plate could be used to conduct heat to subsequent adjacent media M_(n). Although not shown, it is contemplated that fin devices may be installed in the back wall or side walls of the combustion chamber 730 of furnace 700. In addition, the fin devices can be installed in the unit's hood and/or stack. In this way, heat from the chamber can be transferred along the available pathways for beneficial uses.

In the FIG. 3A embodiment, furnace 700 comprises a finned plate 720 and four fins B. It is important to note that any number of fin-to-finned plate combinations could be employed depending on the goal to be achieved. For example, one embodiment could be equipped one finned plate and eight fins. Another embodiment could be equipped with just fins and another could be equipped with just finned plates. It will be apparent to one of ordinary skill in the art from this disclosure the suitable fin device configurations to implement. A unit could be made transportable with the addition of wheels. Some units may be small enough so as to be carried.

In FIG. 3B is shown a retrofit unit to be implemented in conjunction with a device such as an existing residential wood burning stove, i.e., a cast-iron pot-belly stove (not shown). Since it is contemplated that the unit would replace an existing flue pipe, in operation, heat exchanger 800 could be mounted atop the stove and in-line with the flue pipe of the stove. Although the retrofit could be permanently mounted to the stove, it may be desirable to temporarily affix the unit or have it be movable and inspectable for maintenance purposes.

Heat exchanger 800 is equipped with five fins B. A partitioning wall 810 divides fins B₁, B₃, B₅ and fins B₂, B₄. Finned plate 820 overlies the combustion chamber (not shown) of the stove (not shown). A blower/fan 830 may be used to force air movement. Here, fins B originate from an inner portion of device 800 adjacent partitioning wall 810 and extend outwardly through walls 30, 40. In some cases, walls 30, 40 could be cylindrical.

Heat from aperture 850 is directed through device 800. Catalytic devices (not shown) and/or oxygen injectors (not shown) can be utilized if suitable. A portion of available heat is collected by finned plate 820 and transferred along the provided pathway. Air from blower 830 can be used to cool the sides and the rear of unit 800 to optimize heat transfer. Heat can be ventilated from units 800 by means of vents 860.

It is important to note that any number of fin-to-finned plate combinations could be employed depending on the goal to be achieved. In the FIG. 3B embodiment, unit 800 comprises a finned plate 820 and five fins B. Another embodiment could be equipped one finned plate and six fins and so forth. Also, the retrofits could be incorporated into service with furnaces fired by any number of carbonaceous fuel sources, e.g., solid, fossil, biomass, tires, propane, mixed fuels (such as trash, garbage, waste oils), etc. It will be apparent to one of ordinary skill in the art from this disclosure the suitable arrangement to employ.

A dual-unit retrofit is shown in FIG. 3C. Like the embodiment of FIG. 3B, this retrofit unit can be implemented in conjunction with a device such as an existing residential wood burning stove. In effect the existing flue pipe of the stove (typically about 6″ to about 8″ diameter) is replaced with heat exchanger 900. The lower unit 910 is equipped with five fins B and a respective partitioning wall 911. The upper unit 915 is shown equipped with seven fins B and a respective partitioning wall 916. Finned plate 920 overlies the combustion chamber (not shown) of the stove (not shown). A blower/fan 912, 917 may be used to force air movement. Here, fins B originate from an inner portion of devices 910, 915 and extend outwardly through walls 30, 40, which could be cylindrical if desired.

Heat from aperture 950 is directed through device 910. Catalytic devices (not shown) and/or oxygen injectors (not shown) can be utilized if suitable. A portion of available heat is collected by finned plate 920 and transferred along the provided pathway. Air from blower 912, 917 can be used to cool the sides and the rear of respective units 910, 915 to optimize heat transfer. Heat is ventilated from units 910, 915 by means of vents 913, 918, respectively.

In the FIG. 3C embodiment, the dual-unit retrofit comprises a finned plate 920 in the lower unit 910. It is contemplated, however, that both the upper and the lower units could each comprise a finned plate. In addition, any number of fin combinations and fin/finned plate combinations could be used depending on the goal to be achieved. For example, one embodiment could be equipped with five fins and one finned plate in a lower unit and six fins in an upper unit. Another embodiment could be equipped with five fins and one finned plate in each of a lower and an upper unit. Another embodiment could be equipped with just finned plates. Any number of combinations is possible. It will be apparent to one of ordinary skill in the art from this disclosure the suitable fin and/or finned plate configuration.

FIGS. 4A to 4B illustrate how the device of FIG. 1D can be incorporated into a residential heating program. As shown in FIG. 4A, a four-walled heat exchanger 1010 is equipped with three finned plates in furnace embodiment 1000. Finned plate D₁ overlies a combustion chamber 1020 which may vary in shape and form. Each of the finned plates extends outwardly through walls 30, 40. In some cases, device 1010 could be cylindrical.

To facilitate the ability of core inlet I to receive heat from chamber 1020, air movement means may be utilized. An ash pullout bin 1030 can be placed below chamber 1020 for convenience. Aperture 1050 is centrally aligned. Heat from aperture 1050 is directed through device 1010. One or more catalytic devices (not shown) and/or oxygen injectors (not shown) can be strategically mounted so as not to interfere with the function of the finned plates but may aid in enhancing combustion. Combustion air for the furnace can come from domestic or outside air intakes by means of adjustable louvers.

Flow from core inlet I is directed through apertures 1050, 1065, 1075. A portion of available heat is collected by each of the finned plates and transferred along the provided pathways. In this embodiment, the finned plates terminate in the same medium or the atmosphere 1060. Heat transfer between media 1060, 1070 occurs if there is a temperature gradient at the system boundary. Heat of medium 1060 is directed to ducting 1080 where it may be delivered to the living space and medium 1070 by vents V. Heat of medium 1060 may also be directly ventilated from unit 1000 by means of vents locatable in the front of the apparatus.

Although not shown, it is contemplated that fins and/or finned plates may be installed in the back wall or side walls of the combustion chamber 1020 of furnace 1000. In this way, heat flow in the chamber can be transferred along those pathways for beneficial uses. Any number of fin combinations and fin/finned plate combinations could be used depending on the goal to be achieved. It will be apparent to one of ordinary skill in the art from this disclosure the suitable fin and/or finned plate configuration.

In FIG. 4B is shown a heating system utilizing a free-standing open space heating apparatus commonly seen in a lodge. A four-walled heat exchanger 1110 is equipped with four finned plates in furnace embodiment 1100. Finned plate D₁ overlies a combustion chamber 1120 which may vary in shape and form. Each of the finned plates extends outwardly through walls 30, 40. In some cases device 1110 could be cylindrical.

To facilitate the ability of core inlet I to receive heat from chamber 1120, air movement means would be utilized. For example, an extractor hood (not shown) could be mounted in unit 1100 for forced ventilation. One or more catalytic devices (not shown) and/or oxygen injectors (not shown) could be utilized to aid in combustion.

Flow from core inlet I is directed through apertures 1150, 1155, 1165, 1175. A portion of available heat is collected by each of the finned plates and transferred along the provided pathways. In this embodiment, the finned plates terminate in the same medium or the atmosphere 1160. Heat transfer between media 1160, 1170 occurs if there is a temperature gradient at the system boundary. The heat of medium 1160 is directed to ducting 1180 where it may be delivered to the living space and medium 1170 by vents V.

As was discussed above, the finned plate disclosed herein may extend outwardly from the core in conceivably all directions. As long as there is a temperature gradient across a system boundary, the finned plate could conduct heat to any number of media. In FIG. 5A is shown a media profile. The starting point of heat conduction is the region having the highest temperature. In this illustration, the starting point is point “A” which is also referred to as the primary medium M₁. In the case of a finned plate having contact with the primary medium, the region having the highest temperature on the finned plate is also point “A”. In this illustration, point “B” is located to the left of primary medium M₁ while point “C” is located to the right of primary medium M₁. Points B and C are located in fifth medium M₅. If points “B” and “C” are the desired ending points, both ends of a finned plate P would be designed to terminate in M₅. If points “C” and “D” are the desired ending points, one end of a finned plate P would be designed to terminate in M₅ while the other end would be designed to terminate in M₆. Any number of combinations is possible. For example, one end of a finned plate could extend into M₃ while the other end could extend into M₂. In a symmetrical design, the finned plate could terminate in the same media such as the illustration above with points “B” and “C” where each end terminates in M₅. Multiple media M_(n) are contemplated, each potentially becoming a heat transfer interface to bring about the thermal energy “siphoning” process. It will be apparent to one of ordinary skill in the art from this disclosure how to control and/or modify the heat transfer rate to achieve the goal for which the disclosed devices are implemented.

To ensure that heat transfer at each surface boundary is optimized, a good seal between each medium should be achieved. All points of contact between media or environments should be sealed to prevent leakage therefrom so as to prevent losses (or cross contamination) and thereby maximize the amount of heat transferred. Therefore, it is conceivable that heat could be prevented from dissipating in one or more media. A system could be designed so that heat can “bypass” a medium by means of insulators or other controls so that it may be transferred to a destined medium.

In this illustration, it is stated the starting point is point “A” or the region having the highest temperature on the finned plate (also point “A”). It is to be understood, however, that with respect to the devices disclosed herein, the starting point of heat conduction may vary, e.g. in applications involving cooling where heat may travel inwardly or where heat dissipation has occurred in which cases heat may travel inwardly and outwardly as engineered. Here, the depiction of multiple finned plates serves to illustrate that it is possible to create multiple tiers of heat exchange which may extend in any configuration of directions. Using appropriate insulating means, the system can be designed so as to direct heat in any desired direction. For example, if desired, one embodiment of the disclosed device could direct heat from a stationary unit using one or more finned plates but only in the z direction.

FIG. 5B depicts how the finned plates could be looped so as to provide energy for its own system. Assuming that the starting point of heat conduction is “A” and ignoring for now the dotted lines, it can be seen that heat can be transferred to media M₁ and M₁ via finned plate 1204 and to media M₂ and M₁ via finned plate 1201. Similarly, heat can be transferred to media M₂ and M₃ via finned plate 1205. With finned plates 1202, 1203 heat from point “A” that is dissipating via plate 1203 can be looped back to point “A” if desired by running the appropriate medium in plate 1202. This is one advantage of looping finned plates. To achieve this, the ends of finned plates 1202, 1203 can be physically tied together.

A greater advantage of looping finned plates is to adjust the temperature of one or more media for a desired use. Using finned plates 1205 and 1201 to illustrate, assume that the left ends of the plates are physically tied together (see dotted lines) such that both finned plates communicate with a medium M₃. Because finned plate 1205 is close to the heat source, a substantially large amount of heat can be readily transferred to media M₃, whereby the temperature T₁ of M₃ at depth d₁ adjacent finned plate 1205 is raised to T₂. As the fluid mixes, the temperature of M₃ at depth d₂ may not be T₂. Because mixing occurs in M₃ the temperature of M₃ at depth d₂ may be lower than what is required, e.g., for heating a boiler medium. If necessary, the temperature of M₃ at depth d₂ may be augmented by heat transferred via finned plate 1201. Since finned plate 1201 is not as close to the heat source as finned plate 1204, it may be useful to implement a combustion device adjacent the aperture (point “A”) of finned plate 1201 to generate heat for transfer to media M₃. In some instances it may be desirable to slow down the amount and rate of heat transferred. The devices disclosed herein can incorporate media having single or multiple pass flows, parallel flows, counterflows, cross-flows, etc. within or adjacent the devices. Any number of combinations is possible. It will be apparent to one of ordinary skill in the art from this disclosure how to implement the controls necessary to achieve the goal for which the disclosed devices are implemented.

One or more of the disclosed devices can be grouped to form a collective system or gang of devices. An example of a vertical gang of devices can be seen in the retrofit of FIG. 3C. Although examples of the disclosed devices will be discussed below, any number of configurations is possible and should not be limited thereto.

FIG. 6A provides an illustration of how the disclosed devices could be tied together. Here, three FIG. 1D units are joined. Though it appears that the three units are in series, in application they could be configured as suitable. For example, one unit may be positioned in an end of a row of townhouses while the others could be situated in the same or different rows or staggered. Not only can the devices be aligned linearly, a grid pattern may be achieved using appropriate piping and ducting. It will be apparent to one of ordinary skill in the art from this disclosure the placement of the finned plates and tie-ins necessary to achieve the goal for which the disclosed devices are implemented.

In system 1300 units 1301, 1302 and 1303 each comprise a four-walled heat exchanger 1310A, 1310B and 1310C, respectively. Finned plate 1320 is common to devices 1310A, 1310B and 1310C. Specifically, a portion of finned plate 1320 overlies combustion chambers 1331, 1332 and 1333. Finned plate 1330 is common to devices 1310A, 1310B and 1310C.

Finned plates 1340, 1350 and 1360, on the other hand, pertain respectively to devices 1301, 1302 and 1303. Finned plate 1340 extends to the left through media M₂ and M₁ and to the right through media M₃, M₄, M₅, and M₆. Finned plate 1350 extends to the left through media M₁₀, M₉, M₈, M₇ and M₆ and to the right through media M₁₁, M₁₂, M₁₃, and M₁₄. Finned plate 1360 extends to the left through media M₁₆, M₁₅, and M₁₄ and to the right through media M₁₇ and M₁₈.

It is important to note that the numbering of each of the media M is for illustrative purposes. In some cases, one medium could be a unique medium unto itself and in other cases it may designate a medium in common with another. For example, M₂ and M₃ could comprise the same cooling fluid, whereas M₆ could comprise a fluid unique to itself. In some cases however, M₈ and M₁₃ could comprise two different media even though the illustration shows the media are interrelated, and so forth. It is contemplated (but not shown) that each unit in the gang of devices could be distant from one another but the media could still be in communication. Therefore, in a different configuration, M₃ which is shown adjacent heat exchanger 1310A could communicate with M₁₁, as an example, which is shown adjacent heat exchanger 1310B.

Heat from apertures 1370A, 1370B and 1370C is directed through devices 1310A, 1310B and 1310C. A portion of available heat is collected by finned plate 1320 and transferred along its length. In this illustration, heat from units 1301, 1302 and 1303 passing through devices 1310A, 1310B and 1310C may be vented as 1301A, 1302A and 1303A. If desired, heat from 1370A can be transferred via 1320, 1340 and 1330 over various distances to positions in media M₁ and M₂ as well as to positions in media M₃, M₄, M₅, M₆ and so on and dissipated at the same or different rates depending on the selected media and as depicted generally by the arrows. Heat from 1370B can be transferred via 1320, 1350 and 1330 over various distances to positions in, for example, media M₆, M₇, M₈, M₉, M₁₀ as well as to positions in media M₁₁, M₁₂, M₁₃, M₁₄ and dissipated at the same or different rates depending on the selected media and as depicted generally by the arrows. Similarly, heat from 1370C can be transferred via 1320, 1360 and 1330 over various distances to positions in, for example, media M₁₄, M₁₅, M₁₆ as well as to positions in media M₁₇, M₁₈ and dissipated at the same or different rates depending on the selected media and as depicted generally by the arrows. Heat transfer between media occurs as long as there is a temperature gradient at the system boundary. Thus, it is possible to create a dissipation of heat in a desired medium by proper placement of the finned plate and selection of the media. As in the other embodiments, it will be apparent to one of ordinary skill in the art from this disclosure how to implement catalytic devices, oxygen injectors, and blowers/fans (all not shown) so as to achieve the goal for which the disclosed devices are implemented.

Heat dissipates unless it is insulated from doing so. Therefore, heat can also be ventilated from units 1301, 1302 and 1303 by means of vents (not shown). Also not shown are the fin devices that may be installed in the back wall or side walls of the combustion chambers 1331, 1332 and 1333 of units 1301, 1302 and 1303, respectively. In addition, the fin devices can be installed in the hoods and/or stacks. In this way, heat flow in the chamber can be transferred along those pathways for beneficial uses. Exchangers 1310A, 1310B, 13010C could be cylindrical. An ash bin 1381, 1382 and 1383 can be placed below combustion chambers 1331, 1332 and 1333 for convenience.

In FIG. 6B the units introduced in FIGS. 1C and 1D can be joined to form a collective system or gang of devices. Here, two FIG. 1D units are joined to a FIG. 1C unit. Two of the units are shown in series with the third unit being offset at a distance. In application, each group of units could be configured as is suitable. Not only can the devices be aligned linearly, a grid pattern may also be achieved. It will be apparent to one of ordinary skill in the art from this disclosure the appropriate engineering and design necessary to achieve the goal for which the disclosed devices are implemented. See for example FIG. 9C.

In system 1400 units 1401, 1402 and 1403 each comprise a heat exchanger 1410, 1420 and 1430 respectively having any desired configuration, e.g., rectangular and cylindrical (as shown), trapezoidal, pyramid-shaped, etc. Heat exchanger 1410 is equipped with finned plates 1411 and 1412 and fins 1413, 1414, 1415 and 1416. The fins in this embodiment originate in medium A. The fins and finned plates terminate in medium M₁. Medium M₂ represents some environment adjacent the unit 1401. Heat exchanger 1420 is equipped with finned plates 1421, 1422, 1423, 1424, 1425 and 1426. The finned plates in this embodiment terminate in medium M₄. Medium M₃ represents some environment adjacent units 1401 and 1402. Medium M₅ represents some environment adjacent units 1402 and 1403.

Heat exchanger 1430 is equipped with finned plates 1431, 1432, 1433 and 1434. Finned plates 1433 and 1434 terminate in media M₆. One end of finned plate 1431 also terminates in media M₆; however its other end extends to the right through media M₆ and terminates in M₇. One end of finned plate 1432 also terminates in media M₇; however its other end extends to the left through media M₆ and terminates in M₅. Medium M₈ represents some environment adjacent the unit 1403 that is not M₇.

FIG. 7A depicts an embodiment of the disclosed device adapted for use with an internal combustion engine. Heat from the exhaust manifold 1502 of an internal combustion engine 1501 is directed into heater/muffler unit 1500.

In heater/muffler unit 1500 apertures 1505 of finned plates 1506 serve to create orifices through which exhaust and sound waves pass. When a sound wave encounters an aperture 1505, a muffling effect takes place before the sound exits by means of conduit 1510. Part of the wave may be reflected back to the unit's back wall or against other finned plates which can also help to reduce sound. When exhaust encounters an aperture 1505, heat present in the gas can be transferred via finned plates 1506 to media or chamber 1508. Intake air from a car's cabin (not shown) enters via conduit 1504 and can be used for reheating purposes after it passes by the terminus ends of finned plates 1505 in media 1508. A portion of heat can be transferred to the atmosphere within the cabin via conduit 1503 by means of recirculated intake air. Oxygen injectors 1511 can be strategically mounted so as not to interfere with the function of the finned plates but to aid in enhancing combustion. Not only can finned plates 1505 provide a baffling function which can help to reduce sound, they can utilize the exhaust gas for heating the car's cabin (not shown). After being utilized, the exhaust exits by means of conduit 1510. Alternately, heated air can be routed to an adjacent domestic living space. In this latter embodiment (not shown), the exhaust could originate from an internal combustion engine on a trailer. It is conceivable that the heat source could also be a nuclear rod mounted laterally in the apparatus, passing through centrally-aligned apertures.

As stated herein, the finned plates can be selected from materials that are dissimilar from the material used in the unit's walls having relatively low conductivity, and preferably from materials that promote the amount of heat transfer desired. The finned plates may also be selected from materials that are known to be catalysts. If one or more of the finned plates were constructed of a ceramic coated with a metal catalyst, e.g., platinum, rhodium and/or palladium, the device would function as a catalytic converter to help reduce the nitrogen oxide emissions as well as the amount of unburned hydrocarbons and carbon monoxide.

FIG. 7B depicts an embodiment of the disclosed device adapted for use with a cooling pan exposed to moving air. Though the illustration shows unit 1600 positioned laterally, it can have vertical utility. Medium 1601 contained in housing 1602 is in direct communication with one or more finned plates 1603. Finned plates 1603 are mounted in receiving slots S substantially perpendicular to housing 1602. The contact points along slots S should be sealed to ensure a discrete boundary wall between the unit's wall and the finned plates. The ends of the one or more finned plates 1603 are connected to lateral plates 1604, 1605.

A heat source (not shown) can be mounted so as to communicate with one of the lateral plates, either 1604 or 1605. The other lateral plate extends into an outer atmosphere or medium exposed to a cross flow of air. Heat present in the lateral plate adjacent the heat source is transferred to the outer lateral plate exposed to the cross flow of air. Thus, the heat source may be cooled.

It is contemplated that the position of an inner plate (as it relates to an adjacent heat source) may be shifted based on the amount of cooling required. For example, a thermostat (not shown) could communicate a signal to increase or decrease the distance between the heat source and the inner plate. If the distance between the heat source and the inner plate is relatively small, whereby more cooling is required, this could also signal the device creating the cross flow of air to increase its throughput. This device may be useful in applications relating to large main frame computers. In addition, the room air present in a building (not shown) may be drawn by a fan to the inner lateral plate so that the heat may be transferred to the cooler air atmosphere. Like the device of FIG. 1A, a conduit can be connected to the outer lateral plate to transfer heat from the plate to other uses or media M_(n).

Embodiment 1650 of FIG. 7C resembles the embodiment shown in FIG. 1A except that the connecting plates 160 of device 100 connect a staggered pair of fins A while the connecting plates 1660, 1661 of device 1650 connect an aligned set of fins 1603. The set can comprise a pair of fins, or three or four fins, and so on. Connecting plates 1660 can be mounted adjacent a heat source and separated from said heat source by an adjustable distance. Connecting plates 1661 can be mounted adjacent a cooling medium. Heat from the heat source can be transferred from connecting plates 1660 to connecting plates 1661. Like device 1600 disclosed in FIG. 7B the position of connecting plates 1660 may be shifted based on the amount of cooling required. However, here the position of connecting plates 1660 can be shifted independent from one another. One or more conduits (not shown) can also be connected to connecting plates 1661 can be used to transfer the collected heat to other uses or media M_(n).

Although not shown, an embodiment could comprise one or more embodiments 1600 and/or 1650 connected serially. Alternately, one or more fins 1603 could extend through various media. For example, a device 1600 could be mounted vertically in relation to a heated wall of a main frame. Fins 1603 are thus positioned substantially perpendicular in relation to the heated wall. It is contemplated that fins 1603 originating in a medium M₁ could extend through a medium M₂ and terminate in a medium M₃. One or more conduits housing a cooling medium can be mounted in a portion of a fin 1603 to carry heat to one or more uses or media.

FIGS. 8A, 8B depicts a heat exchanger 1700 that can function as a housing for a source of heat to be transferred from the housing core 1710. A source of heat (not shown) could take the form of an armature, shaft, nuclear rod, etc. Heat exchanger 1700 comprises a round finned plate structure 1720 comprising ribs or extensions 1725 which radiate outwardly through medium M₂. Heat from the heat source is collected and conducted by means of inner tube 1723 and ribs 1725 to the outer tube 1728 of finned plate 1720. As shown in FIG. 8B a medium M₂ can be utilized to promote a thermal gradient. In this illustration, medium M₂ is housed in a tube 1730 that encapsulates inner tube 1723. One having skill in the art would understand that the device's core 1710 may also receive heat from the surface of device 1700, whereby heat is transferred inwardly, if so engineered.

It is contemplated that M₂ in FIGS. 8A and 8B may comprise a porous medium that can provide for heat storage and dissipation. For example, the porous medium could take the form of an aggregate such as concrete which is also formable and/or moldable. The advantage of using concrete for example, would be a low cost method of casting in place one or more sections of a heat transfer device. This way, the heat can be collected and dispersed evenly through the concrete encasement or aggregate structure.

In an alternate embodiment (not shown), heat exchanger 1700 could comprise flexible elements so as to be wrapped around a heat source. Inner tube 1723 is positioned adjacent a heat source whereby heat is collected and conducted by means of inner tube 1723 and ribs 1725 to the outer tube 1728 of finned plate 1720.

In another alternate embodiment (not shown), a heat exchanger 1700 could comprise a mesh sheet. To illustrate, it may be useful to envision the unrolling of a flexible version of heat exchanger 1700. In an unrolled assemblage, outer tube 1728 of finned plate 1720 becomes the lower outer edges of the sheet embodiment. Ribs 1725 become vertical extensions of the sheet having a thickness t. Inner tube 1728 of finned plate 1720 becomes the upper outer edges of the sheet embodiment. This type of embodiment could have uses in composites, specialty woven products, textiles, performance fabrics, fiber reinforced materials, etc.

FIG. 9A depicts an embodiment of the disclosed device adapted for long distance transfer of heat. A section 1801 of heat exchanger 1800 comprises at least one round finned plate structure 1820 having a thickness (not shown). Finned plate 1820 comprises ribs 1825 which radiate outwardly through media M₁ and M₂ from an inner ring 1823 to outer ring 1827. Heat is collected at outer ring 1827 (or at ends 1829 of one or more ribs 1825) and conducted therefrom by means of ribs 1825 and inner ring 1823 to core 1810. It is contemplated that one or more sections 1801 can be connected one to another via known fastening means and substantially aligned so as to construct a system capable of making long distance transfers of heat.

As stated herein, the disclosed devices seek to implement finned plates and the use of temperatures of various media so as to optimize the opportunities to recover and make beneficial use of waste heat. In this illustration, medium M₁ is housed in tube 1830 which encapsulates inner ring 1823. Medium M₂ is housed in tube 1840 coincident with outer ring 1827. Cylinder 1850 serves as a protective sleeve which encases the finned plate(s) 1820 and core 1810. Cylinder 1850 could comprise a solar membrane or a low-reflectivity skin that can effectively absorb heat. M₃ denotes a medium between tube 1840 and cylinder 1850 and may comprise an insulating medium to control thermal energy dissipation during long distance or long range thermal energy transfers. A female slot/connector on the inner surface of cylinder 1850 can be designed to receive a male end of a connector located on outer ring 1827 (or vice versa) when cylinder 1850 is slipped over finned plate(s) 1820. M_(X) represents the environment adjacent unit 1800. M_(X) may or may not have the same thermal value at various points along the length of heat exchanger 1800.

Because thermal energy spontaneously flows from one object to another where there is a temperature difference between objects in proximity, heat transfer between the objects cannot be stopped; it can only be slowed down. Core 1810 may be hollow or solid depending on the application and comprises a substantially cool center. As contemplated, heat will be transferred to the system's core 1810 where it can then be directed (work is performed on the system) to beneficial uses downstream. Because the disclosed device is capable of making long distance transfers of heat, heat can be directed to one or more utilities ducted into the system as shown or some medium M_(n). In this illustration, point A is shown to be the initial collection point. This device can be used to transfer heat in solids, liquids, or gas. It is also contemplated that the device could house a nuclear rod or armature in its core.

It is well known that, in the absence of work, thermal energy transitions spontaneously from the areas of high temperature to areas of low temperature. Heat is the amount of energy dispersed to a system at temperature T from the surroundings at a temperature that is only slightly higher than temperature T, e.g., at one degree differential (or vice versa) from the system at only a slightly higher temperature than the surroundings at temperature T. Because the temperatures can be small, the gradual dispersal of heat in either direction is essentially reversible. When two bodies of different temperature come into thermal contact, they will exchange internal energy until their temperatures are equalized thermally. Thus, energy of all kinds disperses or spreads out if it is not hindered from doing so.

As fluid carrying heat travels through the core 1810, heat will attempt to disperse to a cooler medium. To control heat dissipation as a liquid travels through the device carrying heat for beneficial uses; insulators or other entropic controls may be utilized to prevent undesired heat loss and to pull heat back to the core, thereby ensuring that the available heat may be transferred to a destined medium. It is well-known that the system will attempt to reach a point where cylinder 1850, finned plate(s) 1820 and core 1810 will be at the same temperature. In this situation, nothing else can happen although heat exists in the system. As there are no more heat transfers, the heat would be unable to do useful work. Therefore, various media may be employed to influence the entropy of the system and ensure heat transfers. Also, the finned plate(s) 1820 may be strategically placed to draw heat back to the core. It will be apparent to one of ordinary skill in the art from this disclosure how to employ the media and place the finned plates to achieve the goal for which the disclosed devices are implemented. In addition, a skilled artisan would understand that heat can be transferred outwardly from core 1810 if so engineered.

FIGS. 9B, 9C depict a gang of heat exchangers that also incorporate the utility of the long distance transfer of heat described in FIG. 9A. It is contemplated that this system could be used on the industrial scale since it can incorporate thermal energy from multiple fuel sources. System 1900 comprises four heat exchanger units 1901, 1902, 1903 and 1904 that are each capable of receiving waste heat from industrial processes. In this application, units 1901, 1902, 1903 and 1904 would likely comprise the technology of units 400, 500 as shown in FIGS. 1D, 1E. Those embodiments utilize a series of thermally conductive finned plates positioned horizontally, one above the other. In application, units 1901, 1902, 1903 and 1904 could derive waste heat from boilers, industrial incinerators, e.g. facilities that to burn fuels such as mixed waste and/or biomass.

The heat from one or more of units 1901, 1902, 1903, 1904 can be transferred to junction 1905 by means of one or more finned plates FP that are thermally connected thereto. Junction 1905 is similar to the initial collection point “A” described above in FIG. 8A. It is contemplated that core 1910 shown in FIG. 9A is a tube containing liquids, gases, or solids capable of carrying heat from junction 1905. Though not to be limited to these applications, heat transferred via the material in core 1910 could be used to power industrial scale electrical power and utility plants. Core 1910 may be hollow or solid and comprises a substantially cool center. As contemplated, heat will be transferred to the system's core 1910 where it can then be directed (work is performed on the system) to beneficial uses downstream. Because the disclosed device is capable of making long distance transfers of heat, heat can be directed to one or more utilities U_(n) or media M_(n). It is also contemplated that if a particular unit is out of service for scheduled maintenance, as an example, or underperforming, the other units could still function to recover and transfer waste heat to junction 1905 as designed.

The heat from one or more of units 1901, 1902, 1903, 1904 need not be routed to a junction 1905 as it can be directly ducted to core 1910 from 1901, 1902, 1903, 1904 independently. With the technology disclosed herein, heat from one or more of units 1901, 1902, 1903, 1904 may also be transferred directly to one or more utilities X_(n) or media M_(n). Heat can also be transferred to one or more of units 1901, 1902, 1903, 1904 themselves for use therein. It will be apparent to one of ordinary skill in the art from this disclosure how to configure the finned plates, ducting, and associated devices to achieve the goal for which the disclosed devices are implemented.

FIGS. 10A, 10B show how finned plate technology may be adapted for use with solar heat. It is well known that the process of concentrating sunlight on an object can create the high temperatures necessary to undertake a variety of power applications. In FIG. 10A a heat exchanger unit 2100 is capable of receiving radiative heat that is transferred directly into its surface 2110. In this application, unit 2100 comprises a series of thermally conductive finned plates 2120 in a cylindrical housing 2130. Surface 2110 could comprise a solar membrane or a low-reflectivity skin that can effectively absorb heat.

A lower end 2101 of unit 2100 is positioned below ground. Utilizing the cool temperatures of the earth (medium M₁) as well as cool air adjacent the earth (media M₂, M₃), it is contemplated that the core 2140 can be maintained at a lower temperature than surface 2110. Heat from surface 2110 is delivered to a central core location 2140 via finned plates 2120. It is contemplated that core 2140 is a cylinder containing liquids or gases capable of carrying heat. Though not shown, core 2140 could also be bathed in a cooling medium.

Heat flows spontaneously from surface 2110 to core 2140. As heat is transferred from the finned plates, the low-temperature carrying fluid will begin to heat up. Commonly an increase in temperature produces a reduction in density. Heated fluid rises, displacing colder denser liquid which falls. Mixing and conduction result eventually in a nearly homogeneous density and even temperature at which time, gravity and buoyancy forces drive the fluid's movement toward upper end 2102. Heat transferred via the fluid in core 2140 could be delivered to another utility.

FIG. 10B depicts an alternate embodiment adapted for use with solar heat. A heat exchanger unit 2200 capable of receiving radiative heat at its surface 2210 comprises a series of thermally conductive finned plates 2220 in a light pole 2230. Surface 2210 comprises a dark-colored solar membrane or skin that can effectively absorb heat.

A lower end 2201 of unit 2200 could be positioned below ground so that the cool temperatures of the earth (medium M₁) and cool air adjacent the earth (media M₂, M₃) can be used to maintain a low temperature core 2240. Though not shown, core 2240 could also be bathed in a cooling medium. Heat from surface 2210 is delivered to core 2240 via finned plates 2220. It is contemplated that core 2240 is a cylinder containing liquids or gases capable of carrying heat.

The flow of heat is induced by a temperature difference between surface 2210 and core 2240. As heat is transferred from finned plates 2220, the low-temperature carrying fluid in core 2240 will begin to heat up and rise. The surrounding cooler fluid moves to replace it and becomes heated. As the process continues, a convection current forms, driving the heated fluid to upper end 2202 where it may be sent to a utility for beneficial uses.

FIG. 11 illustrates the general application of an embodiment adapted for use with geothermal energy. A heat exchanger 2300 is capable of receiving geothermal radiative heat from indirect magmatic hot rock applications. Unit 2300 comprises thermally conductive finned plates 2320 embedded in a subterranean medium M₁. Finned plates 2320 extend outwardly from core 2310, each terminating in medium M₁. It is contemplated that unit 2300 can be used to transfer heat from solids, liquids, or gas. A core 2310 may be hollow or solid depending on the application and may comprise a cool center.

The depth of the device 2300 would be partially determined by the thermal conductivity of the medium and the goal to be achieved. For example, this unit can be used for cooling the room air present in building 2301. Fan 2302 could draw air from building 2301 to core 2310. Heat is transferred into the cooler subterranean medium by means of the finned plates 2320 in communication with core 2310. In this cooling application, it may be useful to locate the unit 2300 nearer to the earth's surface.

It is commonly known that the earth's temperature changes with depth. As depth increases, the earth's temperature increases. Thus, for heating purposes, it is more likely that the unit 2300 will be located at an increased depth. Heat is collected at finned plates 2320. As heat is transferred from finned plates 2320 to the low-temperature region, core 2310 will begin to heat up. As the process continues, convection drives the heated fluid into building 2301. Fan 2302 may also be used to draw heated air from core 2310 into building 2301, if desired.

This device could also be useful in any number of systems that combine alternate energy sources. In one example, a suitably equipped building is capable of receiving radiative heat at its surface from a solar source and transferring the heat therefrom by means of a series of horizontally positioned conductive finned plates to a receiving body or ducting housed within the building. The receiving body/ducting is thermally connected to the apparatus that is positioned below ground and having a series of horizontally positioned conductive finned plates. Heat is transferred into the cooler subterranean medium by means of the finned plates. The cool temperatures of the earth can be used to maintain a low temperature of the receiving body/ducting medium. It will be apparent to one of ordinary skill in the art from this disclosure how to configure the finned plates in a subterranean medium to achieve the goal for which the disclosed devices are implemented.

In another example (not shown), a building's HVAC system is thermally connected to apparatus having a series of horizontally positioned conductive finned plates that is positioned below ground. Heat is collected at these subterranean finned plates and transferred into ducting of the building's HVAC system by convection. Flow reversing check valves may be utilized to facilitate the self-containment of the system for both heating and cooling purposes.

FIGS. 12A, 12B show examples of how the disclosed devices can be adapted into a system of conventional devices. Larger power systems typically comprise several pieces of equipment. For example, a simple steam power plant may consist of devices such as a boiler, turbine, condenser and pump. The disclosed devices employ one or more heat exchange devices to utilize waste heat and maximize available energy values. The disclosed devices can be installed in conjunction with one or more existing systems to enhance the recovery of waste heat from a combustion source. In FIG. 12A, a FIG. 1D or FIG. 1E device is combined with conventional steam power plant technology. In this example, heat from a combustion source is used directly for utility purposes while the waste heat is transferred to the water in a boiler and then finally to the point of end use.

A source of carbonaceous feedstock 2401 is shown adjacent a conveyer 2402 and a mill 2403. Fuel 2405 is fed to a gas-fired (e.g., natural gas) combustion chamber 2406. The heated products of combustion rise from the combustion chamber 2406 and sequentially impact thermally conductive finned plates, thereby transferring heat present in the gases through the finned plates and into the designated media. For example, gases are directed into four-walled heat exchanger 2410 that is equipped with finned plates 2412, 2414, 2416 and 2418. Excess air 2404 can be injected at inlet I or at apertures 2413, 2415, 2417 or 2419 to enhance combustion.

A portion of available heat is collected by finned plates 2412 and 2414 and transferred along the pathway until each terminates in medium M₁. Heat can be ventilated from M₁ by means of vents (not shown) or by radiation into medium M₂. Heat from M₁ can also be transferred at the boundary between device 2410 and boiler 2460. A portion of available heat from apertures 2413, 2415 is directed through heat exchanger 2410 whereby a portion thereof is collected by finned plate 2416 and transferred along its respective pathway to utilities 2450 or to some medium M_(n). As stated above, heat from the combustion source is used directly for utility purposes. As shown, finned plate 2416 may also receive heat from utilities 2450 or medium M_(n) if so engineered.

The heat that is not used directly for utility purposes is nonetheless beneficially used. As described below, waste heat is transferred to the water in the boiler 2460. Available heat from aperture 2417 is directed through heat exchanger 2410 to finned plate 2418 whereby a portion thereof is collected by finned plate 2418 and transferred until the plate terminates in medium M₃ which may or may not be the same as M₁. A portion of heat from aperture 2419 is used to heat the liquid medium M₄ of steam turbine 2420. Generator 2430 directly extracts electric power for utility purposes by means of steam-driven shaft 2421 of turbine 2420. Steam rises and contacts the evaporator coils 2445 of the condenser system. As steam condenses, it is returned to the system as boiler feed water. Battery 2435 can be used as a storage cell for excess energy that may be subsequently used for condenser, igniter, etc. functions.

It is contemplated that a portion of heat from aperture 2419 could be directed through a venture device to provide for a directed use. For example, it is known in the art to utilize vent gases to drive a turbine device. In the disclosed devices, it may useful to alter the geometry of the inner space to maximize the utility of the gases to be vented.

FIG. 12B illustrates further utility of the 2400 embodiment shown in FIG. 12A. System 2500 is set aboard a train or one or more railcars. This arrangement has utility in instances where power may not be available or reliable, for example, in remote locations or in rescue/hazard situations. In this example, heat from a combustion source is used directly for utility purposes while the waste heat is transferred to the water in a boiler and then finally to the point of end use. It is contemplated that this arrangement could be useful for rescue or hazardous materials cleanup operations. Once an emergency is eradicated or a site has been remediated, the train or railcars could be routed to alternate locations. The use of the system is facilitated in that the device is capable of transporting its own fuel source.

In railcar 2592 is supplied a source of carbonaceous feedstock 2501. Crane 2508 aboard railcar 2591 facilitates the loading of feedstock 2501. Conveyor 2502 conveys feedstock 2501 to mill 2504 aboard railcar 2593. In this embodiment, railcar 2593 also transports a gas fuel tank 2505 to feed an incinerator 2506. If desired, the incinerator may be fed with solid fuels that are locally obtained. For example, trash, wood, garbage, debris, etc. are all potential fuel sources. It is contemplated that this device could be used by forestry managers and others for the burning of slash, field burning and other controlled burns. The heated products of combustion rise from the combustion chamber 2507 and sequentially impact thermally conductive finned plates, thereby transferring heat present in the gases through the finned plates and into the designated media. One or more of the finned plates could be constructed of materials useful in removing most or all pollution emissions. Devices capable of generating excess air to enhance combustion can also be transported by the railcars of this embodiment. As illustrated, the boiler devices are employed in an industrial arrangement. One having skill in the art would understand that modifications of the apparatus and methods disclosed herein could be achieved for the residential and commercial arrangements and still fall within the scope of the disclosure.

In FIG. 12C, a FIG. 1D or FIG. 1E device is combined with conventional boiler technology in an alternate configuration with a compressor 2601 containing a refrigerant. Compressor 2601 increases the pressure and proportionately reduces the volume of refrigerant (not shown) entering the compressor. As it is pressurized, the refrigerant heats up. At an elevated pressure, the energy of the refrigerant can do work downstream in the system. Typically, the heated gas dissipates heat of pressurization by means of heat-exchanging coils (not shown) adjacent the compressor 2601. In this embodiment, one or more thermally conductive finned plates 2610 are arranged to transfer heat present in the heated gas by means of apertures (not shown) mounted in the finned plates 2610 to liquid medium M₁ of boiler unit 2615.

Generator 2630 directly extracts electric power for utility purposes by means of steam-driven shaft 2621 of turbine 2620. As shown, this energy can be routed to utilities 2650 for beneficial purposes. Steam rises and contacts evaporator coils (not shown) of a condenser system (not shown). As steam condenses, it can contact another coil set 2604 before it is returned to tank 2603 containing boiler feed water 2605. Battery 2635 can be used as a storage cell for excess energy that may be subsequently to power one or more units of device 2600, e.g., compressor, condenser, igniter, evaporator, etc. Outlets 2636 can be strategically positioned, for example, in a panel to facilitate the battery usages.

Having transferred its heat to M₁ for steam-generating purposes, cooled refrigerant condenses into liquid form. Since it is still pressurized, it can be routed to an expansion valve 2605 where the gas is allowed to move from a high-pressure zone to a low-pressure zone, thereby causing it to expand and flash evaporate. During the evaporation process, the gas can absorb heat from the inside of an adjacent enclosed space, i.e., an adjacent house (not shown), in turn making the enclosed space cold. The cooled air can provide air conditioning for the adjacent house. The evaporator rejects the absorbed heat to condenser coils 2604 whereby the resulting refrigerant vapor returns to compressor inlet 2602 to complete the thermodynamic cycle. This embodiment could have residential, commercial, and industrial uses.

In a very large scale contemplation, a system of conjoined devices could be designed to collect and deliver thermal energy values anywhere, i.e., all over the country, for any desired purpose. For example, a system could be designed to begin with a solar collection system, whereupon it may tap into geothermal heat. From thence, it may utilize an oceanic system before it taps into a land-based industrial incineration system. It is contemplated that the disclosed devices could be used in conjunction with ocean water or other brine sources to generate steam.

In summary, the devices and methods disclosed herein relate to thermal energy “siphoning” technology or heat transfer technology which can be used in conjunction with any number of waste heat combustion processes using hydrocarbon-based fuel sources in the residential, commercial and utility markets. As stated at the outset, attempts may have been made to capture the waste heat and reuse it. The disclosed devices operate to enhance the recovery of waste heat from a system so that it can be put to beneficial use. In conclusion, the disclosed devices present methods and apparatus to effect heat transfer.

Although the disclosed device and method have been described with reference to disclosed embodiments, numerous modifications and variations can be made and still the result will come within the scope of the disclosure. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. 

1. A device capable of providing for secondary combustion and waste heat recovery, said apparatus comprising: one or more conductive plates mounted substantially transverse an inner space and over an inlet for an exhaust stream from a primary combustion unit, each of said plates further comprising a first end and a second end terminating at a position exterior to said inner space and extendable through one or more media; wherein said exhaust stream enters an aperture in said one or more plates and is directed through said inner space; and wherein a portion of heat of said exhaust stream is transferred by said one or more plates to a medium in communication with said first and second ends of said plate.
 2. The apparatus of claim 1 further comprising one or more conductive fins mounted substantially horizontal to said one or more plates or acutely angled therefrom, each of said one or more fins in spaced and stepped opposition with an opposing conductive fin mounted substantially horizontal thereto or acutely angled therefrom.
 3. The apparatus of claim 1, wherein said aperture is offset from the center of its respective plate.
 4. The apparatus of claim 1, wherein said second end further comprises a front edge and a back edge, each of said edges extendable through one or more media.
 5. The apparatus of claim 1 further comprising a core capable of housing a heat source or medium, said core mounted in spaced relation to an adjacent pair of plates.
 6. The apparatus of claim 5, wherein said core is houseable in said inner space or extendable therefrom.
 7. The apparatus of claim 1 further comprising one or more optional fins mountable in a stack, a chamber, or a hood of said primary combustion unit to transfer a portion of heat from said chamber to a medium in communication with a distal end of said optional fins.
 8. The apparatus of claim 1, wherein a medium in communication with said first and second ends can also be in communication with an adjacent or a distant plate.
 9. The apparatus of claim 8, wherein said distant plate resides in another heat recovery unit.
 10. The apparatus of claim 1, wherein said one or more plates is in common with another heat recovery unit.
 11. The apparatus of claim 1 further comprising one or more catalytic devices mountable in or adjacent to said aperture of said one or more plates to enable further secondary combustion.
 12. A method comprising the steps of: mounting one or more conductive plates in a heat recovery device, each of said plates extending outwardly from an inner space housing a heat-carrying medium, each of said plates having distal ends in communication with a terminus medium; contacting said one or more plates with said heat-carrying medium; and routing a portion of available heat from said heat-carrying medium to said terminus medium by means of said one or more plates.
 13. The method of claim 12, further comprising the step of connecting a distal end of at least two of said one or more plates to adjust a temperature of said terminus medium.
 14. A system comprising: a plurality of combustion devices configured in series, parallel, and/or grid format to form a family or a gang of devices; each of said plurality of combustion devices equipped with a heat exchanger comprising one or more conductive plates mounted substantially transverse an inner space and over an inlet for an exhaust stream, said one or more plates having two ends terminating at a position exterior to said inner space, wherein said exhaust stream is directed through said inner space to make contact with said one or more plates; and wherein a portion of heat of said exhaust stream is transferred by said one or more plates to a medium in communication with said ends.
 15. The apparatus of claim 14, wherein one of said one or more plates can be shared by some or all of said plurality of heat exchangers.
 16. The apparatus of claim 14, wherein said medium can also be in communication with an end of an adjacent or a distant plate.
 17. The apparatus of claim 14, wherein said medium is housed in a core of a heat exchanger is capable of making a long distance transfer of heat.
 18. A heat exchanger comprising: one or more conductive plates comprising ribs which extend radially from a hollow core; said core being capable of housing a heat source; and wherein a portion of heat from said heat source is transferred via said ribs to a medium in communication with an outermost edge of said one or more plates. 